VŠB-TUO acquires a unique metal 3D printer to advance new material development
A unique 3D printer acquired by the Protolab 3D Printing Center at the Faculty of Mechanical Engineering at VŠB-TUO for CZK 22 million through the REFRESH project will open up new opportunities for metal 3D printing. Experts will use this state-of-the-art equipment not only for more efficient production of parts and components for partner companies, but primarily for the development and printing of entirely new materials and the transition from prototyping to serial production.
The uniqueness of the new metal 3D printer lies in its nLIGHT technology, which uses a “doughnut”-shaped laser beam. Unlike conventional printers with a fixed laser beam diameter, this device can dynamically adjust the beam diameter during the printing process.
“When printing thin structures, the beam shrinks; when transitioning to solid sections, it automatically enlarges. This brings us enormous savings in both time and costs. Another key benefit of the device is advanced monitoring of each printed layer. While defects in conventional printers are only detected after the part has been completed, this system provides real-time data on temperatures and processes inside the print chamber. This feedback not only helps reduce scrap but also significantly reduces the need for support structures, which is one of the main goals of the center’s current scientific research,” explained Jiří Hajnyš, head of the Protolab 3D Printing Center, who also works at the Industry 4.0 & Automotive Lab of the REFRESH project.
Researchers expect the new device to bring significant progress in the development and printing of entirely new alloys – advanced materials that companies are currently showing strong demand for, yet that standard commercial 3D printers are unable to process.
“Thanks to the new 3D printer’s highly efficient filtration and exhaust system, we can experiment with materials that require specific conditions during printing. These include, for example, magnesium alloys, carbides, and titanium alloys with active additives. Our goal is not only custom manufacturing but also joint development with industry partners. We can design a material tailored to a specific application, whether in the automotive, defense, or security industries. Moreover, the new metal 3D printer allows us to conduct research efficiently because, compared with standard procedures, we need only a very small amount of expensive metal powder,” added Hajnyš.
Protolab is a state-of-the-art research facility focused on additive manufacturing, 3D scanning, and the development of new materials. As part of REFRESH, it collaborates with companies on innovations that are transforming the way modern components are designed and manufactured.
“This new technology confirms the trend toward so-called Additive Manufacturing 2.0. For our commercial partners, we provide comprehensive solutions ranging from 3D scanning and topological optimization of parts to the actual printing of certified components. The equipment enables high repeatability and process stability, which are essential prerequisites for the deployment of 3D-printed parts in demanding industries such as the automotive and aerospace sectors. We are fully in line with the trend in which 3D printing is shifting from prototype development to serial production,” Hajnyš concluded.
The Protolab 3D Printing Center was established with the goal of providing small and medium-sized businesses with access to modern prototyping technologies, thereby increasing their competitiveness not only within the region but also at the European and global levels. Cutting-edge technologies for industrial 3D printing are very expensive and out of reach for many small and medium-sized businesses. The facility has several state-of-the-art 3D printers for both polymer and metal additive manufacturing. However, the new metal 3D printer is among the most advanced. The only other similar device in the Czech Republic is located at the University of Chemistry and Technology Prague.
