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Brake disc manufactured using the Direct Energy Deposition (DED) process

CSIRO, Australia's national science agency, has developed a novel way to generate metal-ceramic powders for 3D printing. Using this powder as feedstock, optimised direct energy deposition and laser powder bed fusion processes were developed by CSIRO and A*STAR SIMTech as part of an A*STAR – CSIRO Research-industry (2+2) partnership project. Trials to generate 3D printing parts were successfully achieved by Romar Engineering in Sydney, Australia and A*STAR SIMTech who respectively fabricated a prototype brake disc and a topology optimised lightweight air intake manifold. The designs for both parts were generated by Meisterform Pte Ltd, Singapore, in a truly collaborative effort.

Topology optimised lightweight air intake manifold manufactured using the Laser Powder Bed Fusion (LPBF) process

This achievement not only showcases the additive manufacturing capabilities of Romar Engineering but also underscores the feedstock development efforts of CSIRO Manufacturing and the advanced laser powder bed fusion and part optimization capabilities of A*STAR SIMTech.