Elmet Technologies receives US patent for refractory metal additive manufacturing process
Sixth patent in the field covers binder-jet printing and directed energy deposition of tungsten heavy alloys
Elmet Technologies, a fully integrated, US-owned and operated tungsten and molybdenum manufacturer, has received US Patent (no. 12,571,080) for the “Fabrication of Metallic Parts by Additive Manufacturing”. The patent marks the sixth granted to the Lewiston, Maine-based company in the field of powders and processes for additive manufacturing and powder metallurgy applications.
The patented process covers the fabrication of three-dimensional metallic objects using a dry powder bed of substantially spherical composite particles — each comprising a mixture or alloy of constituent metals, including tungsten heavy alloys with controlled additions of nickel, iron, copper, cobalt, or manganese.
Spray drying and optional plasma densification are used to produce highly flowable, densified composite particles suited to binder-jet printing and other powder-bed AM techniques. The invention also covers wire-based directed energy deposition, providing manufacturing flexibility for complex refractory metal alloy components.
Meeting aerospace and defense specifications
Parts produced using the process demonstrated compliance with ASTM B777 Class 1 specifications, including density, hardness, ultimate tensile strength, and elongation requirements.Â
The composite particles exhibit a Hall flow rate ranging from approximately 1 s/50g to 25 s/50g, enabling consistent powder-bed spreading. The plasma densification step minimizes interstitial impurity concentrations — including oxygen, carbon, and trace elements — preserving the mechanical integrity of finished parts.
“This patent reflects the depth of innovation our team has built over years of materials research,” stated Michael T. Stawovy, Co-Inventor and Vice President of Research & Development at Elmet Technologies. “By combining spray drying and plasma densification, we have developed a reliable pathway to produce powders and metallic parts through additive manufacturing that meet the demanding performance standards of our aerospace and defense customers – all from a domestically owned and operated facility.”
Elmet Technologies operates three facilities totaling over 500,000 sq ft across Maine, Ohio, and Michigan, and employs nearly 400 people. The company is ISO9001, AS9100, and International Traffic in Arms Regulations (ITAR) registered.
