Researchers have yet to get the additive manufacturing, or 3D printing, of metals completely down to a science. Gaps in our understanding of what happens within metal during the process have made results inconsistent. But a new breakthrough could grant an unprecedented level of mastery over metal 3D printing.

Using two different particle accelerator facilities, researchers at the National Institute of Standards and Technology (NIST), KTH Royal Institute of Technology in Sweden, and other institutions have peered into the internal structure of steel as it was melted and then solidified during 3D printing. The findings, published in Acta Materialia, unlock a computational tool for 3D-printing professionals, offering them a greater ability to predict and control the characteristics of printed parts, potentially improving the technology’s consistency and feasibility for large-scale manufacturing. 

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