Engineered to accelerate the commercialization of next-generation metal additive manufacturing through full-system product development and advanced engineering analysis
An additive manufacturing company sought to commercialize a novel metal 3D inkjet printing process originally developed at MIT. While the underlying technology had demonstrated promise in research environments, it had never been successfully commercialized as a production-ready system.
The client needed to transform an early-stage concept into a functional alpha machine capable of producing high-resolution metal components while meeting aggressive performance, reliability, and manufacturability requirements. The project demanded micron-level precision, stable powder deposition, and repeatable operation within a tightly controlled inert environment.
Compounding the technical challenges was an aggressive schedule. A process that would traditionally require several years of development needed to be compressed into approximately ten months, with a functional demonstration machine delivered in just twenty weeks for a major industry tradeshow.
The client partnered with Re:Build DAPR to serve as an extension of its engineering team, providing complete product development support from process validation and concept refinement through machine design, analysis, integration, and alpha system delivery.
Re:Build DAPR began by collaborating closely with the client during the early stages of process development and proof-of-concept testing. Custom test rigs were developed to evaluate powder flow characteristics, powder delivery methods, carriage motion dynamics, and binder jetting performance.
A major focus of the project involved understanding the interactions between motion systems, powder behavior, vibration, thermal conditions, and environmental controls. Because the printing process required micron-level layer consistency, even small disturbances in structural stiffness, airflow, temperature, or machine vibration could negatively affect print quality.
The engineering team performed extensive structural, thermal, vibration, motion, and fluid-flow analysis to identify potential performance limitations and optimize system architecture. Special attention was given to developing a controlled build environment capable of maintaining stable temperature, pressure, and inert gas conditions throughout the printing process.
To meet the aggressive development schedule, Re:Build DAPR applied a rapid product development strategy that balanced innovation, manufacturability, and commercialization readiness while maintaining a focus on long-term scalability.
Re:Build DAPR designed and built a first-generation metal 3D inkjet printer capable of producing metal components through a high-speed binder jetting process.
At the core of the system was a precision powder bed architecture designed to support repeatable micron-level powder deposition and layer control. A high-speed multi-axis carriage system distributed and leveled metal powder while binder jetting technology selectively deposited material to create complex three-dimensional parts.
The machine incorporated a sealed build chamber with tightly controlled temperature, pressure, and inert gas flow to ensure process stability and maintain consistent material properties throughout the build cycle. Advanced environmental controls prevented contamination and minimized process variability that could impact part quality.
To achieve the required precision and reliability, Re:Build DAPR engineered a lightweight aluminum chassis that reduced structural loading while maintaining stiffness and dimensional stability. Extensive simulation and analysis validated machine performance under demanding operating conditions and helped optimize manufacturability for future production systems.
The resulting platform integrated mechanical systems, motion control, powder handling, environmental controls, and advanced process engineering into a fully functional alpha machine capable of demonstrating the viability of the technology.
Re:Build DAPR successfully delivered a fully functional alpha printer on schedule, enabling the client to showcase its technology at a major industry tradeshow.
The completed system demonstrated repeatable micron-level powder deposition, stable process performance, and high-resolution part production while validating the commercial potential of the client’s metal additive manufacturing technology. The project successfully transformed a promising research concept into a working product platform capable of supporting future commercialization efforts.
By compressing a traditional multi-year development cycle into approximately ten months, Re:Build DAPR helped accelerate the client’s path to market while reducing technical risk through rigorous engineering analysis, testing, and validation.
The success of the alpha platform established a foundation for continued product development, additional machine iterations, and future commercialization initiatives.
The alpha printer platform included:
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