America Makes selects 6K Additive for PADAM project

6K Additive, a division of 6K, has been selected by America Makes, the National Additive Manufacturing Innovation Institute, for its Powder Alloy Development of Additive Manufacturing (PADAM) project. 6K Additive will work in partnership with project lead, Castheon. The project is part of the $6M PADAM project funded by the Air Force Research Laboratory (AFRL). The PADAM program specifically targets the cost-efficiency and performance enhancement of Nb C-103 powder feedstock by qualifying an extended particle size distribution (PSD) for both laser powder bed fusion (PBF-LB) and directed energy deposition (DED) methods.

C-103 is a niobium alloy used in high-temperature applications. While C-103 has historical success in space-flight applications, there are significant MRL maturation opportunities identified to improve productivity, affordability, material, and design maturity. This project is expected to improve material availability and decrease the cost for C-103 by expanding the supply base and utilizing a broader range of particle size distribution (PSD). Using PBF-LB in conjunction with DED, a wider range of PSD can be used, thus efficiently utilizing more of the powdered C-103 produced. The selected final materials will undergo rigorous testing led by NASA Glenn Research Center and NSL Analytical. Lockheed Martin and Firefly Aerospace will serve as production transition partners – further maturing refractory AM materials for thermal protection systems and space propulsion applications.

“We are very excited to be working alongside Castheon, leading defense primes, and even other powder manufacturers to advance C-103 use in additive manufacturing for the defense industry,” said Frank Roberts, President of 6K Additive.

6K Additive’s UniMelt microwave plasma process for producing powders, such as C-103 from revert sources, lowers cost and increases efficiency for high-temperature and space applications.

“We are embarking on an incredibly exciting era across the AM sector. Exploring the possibilities of AM material applications is a step in the right direction with considerable implications for the future of aerospace and defense,” said Brandon Ribic, Technology Director at America Makes. “America Makes is incredibly fortunate to have the support of OSD ManTech and AFRL and the engagement of the brightest minds in the country who will be collaborating to revolutionize this technology.”

“Working alongside 6K Additive and other industry leaders on this project allows us to push the boundaries of what’s possible. Castheon’s focus on advancing niobium alloys through AM not only improves material performance but also plays a critical role in strengthening our nation’s defense capabilities. We’re proud to contribute our expertise to this initiative,” said Greg Pilon, Chief Revenue Officer of ADDMAN.