At HBD, we’re always looking for new ways to push the boundaries of metal additive manufacturing, and 2024 has been a year packed with exciting advancements. From support optimization to batch production solution, here’s a closer look at how these advancements align with the industry’s broader goals and trends.  

96% Support Reduction: Enhancing Sustainability and Efficiency

In aerospace, where every gram matters, our latest support optimization technology has made strides. By reducing the unsupported angle requirement from 45° to 6°, we’ve been able to decrease the volume of support structures for turbine components by 96%. This means less material consumption and more streamlined post-processing—an approach that reflects the industry’s growing emphasis on sustainable and cost-effective manufacturing.  

This development comes at a time when the aerospace sector is actively seeking lighter, stronger, and more efficient components, with additive manufacturing playing a pivotal role in achieving these goals.  

Topology Optimization: Lightweight Solutions for Modern Challenges

The push for lighter, more efficient designs is shaping many industries, including drones. Using topology optimization, HBD has demonstrated how intricate, lightweight drone frames can be manufactured to reduce energy consumption and improve performance.  

As the adoption of drones expands into fields like logistics, agriculture, and surveillance, such solutions are crucial. Lightweight structures not only enhance battery life but also contribute to the broader movement toward energy-efficient systems.

Medical Batch Production: Balancing Customization and Efficiency

Personalization has always been a cornerstone of medical advancements, particularly in implants. HBD’s ability to print 288 acetabular cups in a single batch highlights how customization can coexist with scalability. By stacking these components and fine-tuning the printing process, we’ve shown that mass production needn’t compromise on quality or adaptability.  

This achievement aligns with a global trend: leveraging additive manufacturing to address the demand for personalized medical solutions while managing costs and lead times effectively.  

Consumer Electronics: Meeting Batch Production Demands with Precision

As consumer electronics grow increasingly complex, the need for precision manufacturing has never been greater. With the HBD 400’s six-laser system, we printed 1,956 smartphone hinge covers in just 52 hours. These components combine durability with intricate designs, meeting the exacting standards of modern electronics.  

This case study underscores the potential of additive manufacturing in batch production—a direction many in the industry are exploring to stay competitive in fast-paced markets.  

Precision Engineering: Innovations in Thermal Management

Efficient heat dissipation is a cornerstone of modern electronics and engineering. With the HBD 200, we achieved grille wall thicknesses of 0.08 mm and gaps of 0.2 mm for heat sinks, demonstrating a capability to produce complex designs with high precision. These advancements not only improve thermal performance but also reduce production costs and lead times—objectives shared by manufacturers worldwide.  

As precision engineering demands grow, metal 3D printing continues to offer new ways to address these challenges.

What’s Next?

As we continue to innovate, our goal is simple: to enable industries to achieve more with metal 3D printing. Whether it’s in aerospace, consumer electronics, healthcare, or precision engineering, we’re proud to contribute to the realization of additive manufacturing’s future.

Ready to join us on this journey? Let’s explore how HBD can elevate your projects to new heights!