If you’re in aerospace, Автомобиль, или тяжелая техника, Вы, наверное, спросили: What is big metal additive manufacturing, and how can it transform my production? Проще говоря, big metal additive (also called large-format metal 3D printing) is a technology that creates full-scale, high-strength metal parts—often larger than 1 meter—by building them layer by layer, instead of cutting or shaping from a solid block. Unlike small-scale metal 3D printing (used for tiny components like medical implants), this technology handles massive parts like aircraft wings, Кадры грузовиков, or industrial turbine casings. Самое большое преимущество? Это устраняет отходы, сокращает время выполнения заказов до 50%, и позволяет создавать детали, которые были невозможны традиционными методами.. Давайте погрузимся во все, что вам нужно знать.
Что такое крупное аддитивное производство металлов?
Чтобы понять big metal additive, let’s break it down from the basics. Traditional metal manufacturing (like forging or machining) starts with a large metal billet and removes material to make a part—this is called “subtractive” manufacturing. Big metal additive, напротив, is “additive”: it uses metal powders, провода, or sheets and fuses them layer by layer (usually with lasers, electron beams, or arc welders) to build the part from the ground up.
The key difference between big metal additive and standard metal 3D printing is size capability. Most desktop metal 3D printers max out at parts the size of a shoebox. Big metal systems, однако, can handle build volumes as large as 5m x 3m x 2m (like the ones from companies like Relativity Space or GE Additive). This makes them critical for industries that need large, complex metal parts—think aerospace (rocket boosters), энергия (wind turbine hubs), или морской (Корабли стволы винта).
Основные технологии, обеспечивающие присадку для крупных металлов
Not all big metal additive systems work the same way. The three most common technologies are:
- Прямое осаждение энергии (Дед)
This is the most popular method for large parts. It uses a nozzle to blow metal powder or feed metal wire into a high-energy beam (лазер, электронный луч, или плазменная дуга), which melts the material and deposits it onto a build plate. DED is fast and can even repair existing large parts (like fixing a cracked turbine blade). Например, Siemens Energy uses DED to repair gas turbine components that weigh over 1,000 kg—saving millions compared to replacing the part.
- Порошковая кровать слияние (PBF) для больших частей
Traditional PBF (used for small parts) spreads a thin layer of powder and melts it with a laser. Large-format PBF systems (like EOS’s M 400-4) scale this up, but they’re less common than DED because powder beds for big parts are harder to keep uniform. Однако, PBF offers better precision for detailed large parts—like satellite structures.
- Производственная аддитивное производство (Вызов)
WAAM uses a standard welding arc to melt metal wire, making it one of the cheapest and fastest big metal methods. It’s ideal for ultra-large, less complex parts—like construction beams or offshore oil rig components. В 2024, a team in the UK used WAAM to build a 6-meter-long bridge support beam in just 3 дни, по сравнению с 2 weeks with traditional welding.
Почему промышленность принимает крупные металлические добавки
The shift to big metal additive isn’t just a trend—it’s driven by tangible benefits that solve long-standing industry problems. Let’s look at the top reasons companies are investing in this technology, с реальными примерами.
1. Сокращение отходов и снижение затрат
Traditional subtractive manufacturing for large metal parts can generate up to 70% напрасно тратить. Например, making a single aircraft wing spar from a solid aluminum billet might require cutting away 1,500 kg of metal to get a 300 kg part. Big metal additive, напротив, uses only the material needed for the part—cutting waste to less than 10%.
Тематическое исследование: Boeing adopted big metal additive for a 2-meter-long structural part in its 787 Дримлайнер. До, the part required 12 separate components (machined and welded together) and generated 800 kg of waste. With additive, Boeing makes the part in one piece, cuts waste by 90%, and saves $300,000 за самолет.
2. Более быстрое время выполнения
Waiting for large metal parts (like custom turbine casings) can take 6–12 months with traditional methods—especially if the part needs a custom mold or forging die. Big metal additive eliminates the need for tooling, so lead times drop to 2–4 months.
Точка данных: Согласно 2025 report by the Additive Manufacturing Users Group (AMUG), 78% of companies using big metal additive reported lead time reductions of 30% или больше. One heavy machinery manufacturer cut the time to make a 1.8-meter excavator arm from 5 месяцы до 6 недели.
3. Свобода дизайна для сложных деталей
Traditional manufacturing limits design—you can’t make parts with internal channels, hollow sections, or organic shapes without expensive secondary operations. Big metal additive lets engineers create “topologically optimized” parts: зажигалка, сильнее, and tailored to their exact function.
Пример: GE Renewable Energy used big metal additive to redesign a wind turbine hub. The original hub was 1.2 метры шириной, взвешен 800 кг, and had 10 сварные детали. The additive version is 20% зажигалка (640 кг), made in one piece, and has internal cooling channels that improve performance. It also lasts 15% longer because there are no welds (a common failure point).
Ключевые области применения крупных металлических добавок по отраслям
Big metal additive isn’t a one-size-fits-all technology—it’s adapted to solve unique challenges in different sectors. Below’s how major industries are using it today.
Аэрокосмическая и защита
This is the largest adopter of big metal additive, thanks to the need for lightweight, высокопрочные детали. Общие приложения включают в себя:
- Rocket components (НАПРИМЕР., Relativity Space’s Terran R rocket uses 3D-printed engines and fuel tanks that are 3 метры высотой)
- Структурные детали самолетов (крылья, фюзеляжи, and landing gear components)
- Военные транспортные средства (custom armor plates and engine parts)
Authority Source: NASA’s Marshall Space Flight Center uses big metal additive to make 2.4-meter-long rocket nozzles. The agency reports that additive parts are 40% lighter than traditional ones and can withstand the extreme heat of rocket launches better.
Энергия (Масло, Газ, и возобновляемые источники энергии)
In the energy sector, big metal additive solves two big problems: making parts that resist corrosion (for oil rigs) and creating large, complex components for renewables. Applications include:
- Offshore oil rig valves and connectors (made from corrosion-resistant alloys like Inconel)
- Wind turbine hubs and nacelle components
- Nuclear reactor parts (additive lets manufacturers make parts with fewer joints, снижение рисков утечки)
Тяжелое машиностроение и автомобилестроение
For companies making trucks, экскаваторы, or construction equipment, big metal additive cuts costs on custom or low-volume parts. Примеры включают:
- Excavator arms and bucket teeth (optimized for strength and weight)
- Truck frame rails (made in one piece instead of 5–6 welded sections)
- Custom tooling for automotive factories (additive makes tooling in days instead of weeks)
Строительство
While still emerging, big metal additive is starting to transform construction—especially for large, Прочные структуры. В 2024, a company in the Netherlands used WAAM to build a 10-meter-long steel bridge. The bridge took 2 weeks to print (против. 2 месяцы с традиционными методами) и использует 35% less steel.
Проблемы, связанные с добавками крупных металлов (и как их преодолеть)
Despite its benefits, big metal additive isn’t without hurdles. Understanding these challenges is key to successfully adopting the technology.
1. Высокие первоначальные инвестиции
Big metal additive systems are expensive—they can cost \(500,000 к \)5 миллион, plus ongoing costs for metal materials (which are 2–3x more expensive than traditional metal stock).
Решение: For small to mid-sized companies, consider “additive service bureaus” (like Proto Labs or 3D Systems) that let you outsource big metal printing. This avoids upfront costs. Larger companies can also lease equipment or partner with technology providers (НАПРИМЕР., GE Additive offers “pay-per-part” models).
2. Контроль качества и сертификация
Large metal parts need to meet strict industry standards (НАПРИМЕР., ASTM for aerospace or API for oil and gas). Ensuring every layer of a 2-meter part is uniform and free of defects (like cracks or porosity) is challenging.
Решение: Use advanced monitoring tools—like in-process cameras, thermal sensors, or AI-powered software (НАПРИМЕР., Sigma Labs’ PrintRite3D)—that track the printing process in real time. These tools can detect defects as they happen, not after the part is finished. Также, work with certification bodies early: organizations like AS9100 (для аэрокосмической промышленности) now have guidelines for additive parts.
3. Материальные ограничения
Not all metals work well with big metal additive. Общие материалы включают алюминий, титан, нержавеющая сталь, and Inconel—but exotic alloys (like hafnium or tungsten) are harder to print because they require extremely high temperatures.
Решение: Partner with material suppliers to develop custom alloys for additive. Например, BASF and EOS recently launched a new aluminum alloy (AlSi10Mg+) optimized for large-format PBF. Его 15% stronger than standard aluminum and prints with fewer defects.
4. Пост обработки потребностей
Most big metal additive parts need post-processing—like machining to smooth surfaces, heat treatment to improve strength, или живопись. Для больших частей, this can add time and cost.
Решение: Integrate post-processing into your design. Например, design parts with “self-supporting” structures to reduce the need for support materials (which require removal). Some systems (like DMG MORI’s LASERTEC 65 3Дюймовый) combine 3D printing and machining in one machine, cutting post-processing time by 40%.
Взгляд Yigu Technology на добавку крупных металлов
В Yigu Technology, we believe big metal additive is no longer a “future technology”—it’s a critical tool for industries looking to stay competitive. From our work with automotive and energy clients, we’ve seen firsthand how it solves two of the biggest pain points: waste and lead times. Например, a client in the heavy machinery sector cut the cost of a custom 1.5-meter part by 35% using our big metal additive services, while reducing lead time from 4 месяцы до 6 недели.
We also see sustainability as a key driver. By using recycled metal powders and optimizing part designs for weight, we help clients reduce their carbon footprint—something that’s becoming increasingly important for both regulatory compliance and customer trust. As the technology evolves, we expect to see even more industries adopt big metal additive, especially in construction and marine, where the need for large, durable parts is high.
FAQ About Big Metal Additive Manufacturing
- How big can parts made with big metal additive be?
Current systems can print parts up to 5m x 3m x 2m (Длина x ширина x высота). Some companies are developing systems that can handle parts over 10 метры длиной, which will be used for construction and shipbuilding.
- Is big metal additive more expensive than traditional manufacturing?
It depends on the part. Для небольших объемов, сложные части (НАПРИМЕР., custom turbine casings), big metal additive is often cheaper (saving 20–40%) because it eliminates tooling costs. Для большого объема, Простые части (НАПРИМЕР., standard bolts), traditional manufacturing is still cheaper.
- What metals can be used in big metal additive?
The most common metals are aluminum (легкий вес, используется в аэрокосмической промышленности), титан (сильный, used in medical and defense), нержавеющая сталь (коррозионная устойчивость, used in energy), и insonel (теплостойкий, used in turbines). New alloys are being developed every year, including recycled and bio-based metals.
- How long does it take to print a large metal part?
It varies by size and complexity. A 1-meter turbine blade might take 8–24 hours, while a 5-meter bridge support could take 3–7 days. This is still 30–70% faster than traditional manufacturing for custom parts.
- Are big metal additive parts as strong as traditionally made parts?
Yes—often stronger. Additive parts can have uniform grain structures (thanks to controlled cooling) and fewer welds (a common weak point). Например, aerospace-grade additive titanium parts have a tensile strength of 900 МПА, по сравнению с 800 MPa for forged titanium.