Advanced metal additive manufacturing (AM) technologies are rapidly evolving to enable cost-competitive, high-throughput production of structural and functional metal components. This workshop focuses on the expansion of metal binder jetting, Directed Energy Deposition (DED), and metal filament extrusion as scalable alternatives to traditional laser powder bed fusion systems, with the objective of reducing part costs and expanding industrial adoption.

The sub-workshop explores high-speed binder jetting with sintering, wire- and powder-based DED systems, and extrusion-based metal printing (bound metal deposition). Key topics include densification strategies, microstructural control, material qualification, post-processing optimisation, and integration into hybrid manufacturing environments.

Presentations will examine productivity gains, material efficiency, and energy consumption, alongside challenges such as shrinkage control, surface finish, dimensional accuracy, and certification for critical industries. Academic speakers will highlight advances in metallurgy, sintering science, and process modelling, while industry leaders will provide insights into scaling production lines, reducing cost-per-part, and achieving serial manufacturing readiness.

The workshop aims to provide a comprehensive understanding of emerging cost-efficient metal AM technologies and their role in transforming metal component production across automotive, aerospace, tooling, and energy sectors.

Extended Key Takeaways & Outputs

• Comparative analysis of binder jetting, DED, and metal extrusion technologies

• Identification of bottlenecks in densification, accuracy, and certification

• Strategies for reducing cost-per-part and increasing throughput

• R&D priorities in metallurgy, sintering, and hybrid manufacturing integration

• Roadmap for scaling advanced metal AM into serial industrial production