New materials and innovative production technologies complement the established sectors within the metal industries. Of key importance is the digitalisation of the process chain. Almost an ideal model for complete digital production from design on screen to the finished part, are the generative procedures of 3D printing. Additive manufacturing based on metals allows for a maximum of creative freedom combined with tool-less production of metal parts. Melting metal using lasers has allowed 3D printing to gain importance as a competitive production technology, especially where limited numbers of production, complicated geometry and a high degree of customisation are required.
Additive manufacturing supplements traditional methods and can be integrated into an existing production. Sheet metal processing companies are aware of the advantages of tools for shaping sheet metal which have been produced by additive manufacturing and feature cooling vents close to the contours, steel producers are expanding their business with metal 3D printing. For example by printing large spare parts on demand, for the steel production or mining industries. The production of metal powders for additive manufacturing is proving to be an interesting side business for steel producers to use their production waste. Mechanical engineers in the metallurgical sector are expanding their business by constructing the powder spray aeration systems necessary for the production of metal powders. With additive manufacturing, as a supplement to established manufacturing processes like the use of CNC systems for the series production of plant components, constructors, too, have almost no limits when it comes to plant engineering in the metallurgical sector.
Direct and indirect additive technologies play a double part in the foundry sector. Direct metal printing paves the way for companies to special orders which they would not have been able to meet through classic casting. Regarding indirect methods, i.e. additive manufacturing of the mould, for example from sand, with a 3D printer, thanks to a quick and tool-less manufacture of moulds, prototypes can be cast in a short time while also saving on costs.
But classic shaping methods like casting are also experiencing a validation through digitalisation and continuing further development. One impressive example from pressure casting is so-called mega or giga casting, the casting of large light metal components. In only a single cast component, different functions can be integrated.
