The proposed invention of a low-cost machine allows for never seen scalability in metal AM, allowing for smaller manufacturers to scale by taking advantage of meaningful order quantities and compete with the resources of large conglomerates. In addition, procurement for low to medium volume order quantities (1000 - 20,000 pieces) is incredibly challenging with respect to high cost and long lead times. In developing a low-cost AM alternative, the goal of the proposal is to allow an estimated over 50,000 American manufacturers to capitalize on the benefits of AM and simultaneously compete in an ultra-competitive, highly globalized manufacturing industry. This proposal re-examines the material performance, machine cost and reliability requirements necessary for a novel metal AM system to satisfy most American manufacturers' needs. While these manufacturers require high performance, they cannot currently afford to take advantage of AM benefits due to the high capital expenditure, maintenance, and operating costs associated with current commercial technologies. The proposed project calls into question the performance requirements that most American manufacturers have for industrial grade stainless steel parts. Current metal AM platforms use expensive core components and consumable materials in high-priced machines that produce 99.9% dense parts. This SBIR Phase II Project aims to tackle the two greatest barriers to technology adoption associated with metal additive manufacturing (AM) - cost and quantities.

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