From rockets to electric motors: ETH team builds 3D printer for multi-metals

3D Printing for Aerospace and Industry From Rockets to Electric Motors: ETH Team Builds 3D Printer for Multi-Metals

2025-10-23 From Susanne Braun Susanne Braun | Translated by AI 2 min Reading Time

With the help of lasers, researchers at ETH Zurich simultaneously melt multiple metals using a 3D printing process, and that in comparatively short time. The patented process aims to open up new possibilities for aerospace and industry.

In the new 3D printer, two different materials are simultaneously melted by the laser on the rotating platform.(Image: Michael Tucker / ETH Zurich) — In the new 3D printer, two different materials are simultaneously melted by the laser on the rotating platform.
(Image: Michael Tucker / ETH Zurich)

One of the greatest advantages of 3D printing is that almost any conceivable geometry can be manufactured, regardless of how complex, intricate, or delicate it is. While traditional methods such as milling, casting, or injection molding are limited by tools, molds, and machining directions, 3D printing builds the component layer by layer directly from the digital model. This gives designers significantly more freedom in design and enables lighter, more efficient, and functionally integrated components.

This flexibility should also be reflected in the speed of additive manufacturing, concluded a student team from ETH Zurich. As part of the Rapture focus project, the group developed a laser melting machine designed to accelerate 3D printing of metal parts and make it more cost-effective.

Gallery

A completed vane ring for a high-pressure turbine with a diameter of 75 millimeters (approx. 3 inches).(Image: Michael Tucker / ETH Zurich)

The system combines a rotating platform with the ability to rotate powder and gas nozzles during the process. This allows layers of different materials to be continuously applied and melted without needing pauses between steps. The machine is particularly suitable for cylindrical components.

Multi-metal technology patented

The machine can process two different metals simultaneously, allowing for the production of components with combined material properties – for example, copper for heat conduction inside and nickel alloys for heat-resistant outer surfaces. "The machine can simultaneously apply powder and fuse it with a laser, significantly increasing productivity. For cylindrical components, manufacturing time is reduced to less than a third," it is explained. The project addresses applications such as the production of rocket nozzles or turbines, but is also suitable for other uses in mechanical engineering.

The six-person team developed the prototype within nine months at the Laboratory for New Manufacturing Technologies under the leadership of Professor Markus Bambach and scientist Michael Tucker. Initial components with diameters of up to 20 centimeters (approx. 7 inches) have already been produced. The ETH has filed a patent for the innovative multimetal technology, and the project has been nominated for the Spark Award. In the future, the technology is to be further scaled and applied with industrial partners. Work is now underway to scale the process to higher speeds and larger diameters. (sb)

Subscribe to the newsletter now

Don't Miss out on Our Best Content

Business E-mail

Please enter a valid mailadress.

By clicking on „Subscribe to Newsletter“ I agree to the processing and use of my data according to the consent form (please expand for details) and accept the Terms of Use. For more information, please see our Privacy Policy. The consent declaration relates, among other things, to the sending of editorial newsletters by email and to data matching for marketing purposes with selected advertising partners (e.g., LinkedIn, Google, Meta)

Date: 08.12.2025

Naturally, we always handle your personal data responsibly. Any personal data we receive from you is processed in accordance with applicable data protection legislation. For detailed information please see our privacy policy.

Consent to the use of data for promotional purposes

I hereby consent to Vogel Communications Group GmbH & Co. KG, Max-Planck-Str. 7-9, 97082 Würzburg including any affiliated companies according to §§ 15 et seq. AktG (hereafter: Vogel Communications Group) using my e-mail address to send editorial newsletters. A list of all affiliated companies can be found here

Newsletter content may include all products and services of any companies mentioned above, including for example specialist journals and books, events and fairs as well as event-related products and services, print and digital media offers and services such as additional (editorial) newsletters, raffles, lead campaigns, market research both online and offline, specialist webportals and e-learning offers. In case my personal telephone number has also been collected, it may be used for offers of aforementioned products, for services of the companies mentioned above, and market research purposes.

Additionally, my consent also includes the processing of my email address and telephone number for data matching for marketing purposes with select advertising partners such as LinkedIn, Google, and Meta. For this, Vogel Communications Group may transmit said data in hashed form to the advertising partners who then use said data to determine whether I am also a member of the mentioned advertising partner portals. Vogel Communications Group uses this feature for the purposes of re-targeting (up-selling, cross-selling, and customer loyalty), generating so-called look-alike audiences for acquisition of new customers, and as basis for exclusion for on-going advertising campaigns. Further information can be found in section “data matching for marketing purposes”.

In case I access protected data on Internet portals of Vogel Communications Group including any affiliated companies according to §§ 15 et seq. AktG, I need to provide further data in order to register for the access to such content. In return for this free access to editorial content, my data may be used in accordance with this consent for the purposes stated here. This does not apply to data matching for marketing purposes.

Right of revocation

I understand that I can revoke my consent at will. My revocation does not change the lawfulness of data processing that was conducted based on my consent leading up to my revocation. One option to declare my revocation is to use the contact form found at https://contact.vogel.de. In case I no longer wish to receive certain newsletters, I have subscribed to, I can also click on the unsubscribe link included at the end of a newsletter. Further information regarding my right of revocation and the implementation of it as well as the consequences of my revocation can be found in the data protection declaration, section editorial newsletter.