PI: Sneha Prabha
University: Carnegie Mellon University
Industry Partner: Metal Powder Works
The Pennsylvania-based company Metal Powder Works (MPW) sustainably produces low-cost, high strength Al7075 powder using 40% less energy and 89% lower emissions than traditional methods. Additive manufacturing (AM) enables lightweight components, but lower build rates from powder bed fusion counter sustainability benefits. In addition, AM with aluminum results in cracking. Our objective is to develop AM technology to produce crack-free, near net shape aluminum components from MPW's sustainable powder with higher deposition rates compared to state-of-the-art near net manufacturing. We will collaborate with other Pennsylvania manufacturers like Cumberland Additive and Jeol USA for industrial scale-up at Neighborhood 91. Success will expand MPW's customer base while advancing sustainable AM capabilities. This project brings together industry and academia in Pennsylvania to transform aluminum manufacturing through innovative manufacturing and a focus on sustainability. Students gain expertise valuable to partner companies. Overall, this collaborative approach will enable faster, defect-free additive manufacturing using sustainably produced aluminum.