Argon vs. Nitrogen – Choosing the Right Shielding Gas in Metal AM In powder bed fusion systems, the role of shielding gas is often underestimated. Yet, the choice between argon and nitrogen can profoundly impact the final properties of 3D-printed metal parts. These ... Jan 7, 2026 Repeatability and Process Control
Scan Strategy Isn’t a Detail — It’s a Structural Foundation In metal additive manufacturing, residual stress is an invisible but powerful force that can distort parts, crack surfaces, or even cause complete build failures. One of the most effective ways to con... Jan 7, 2026
Denser Isn’t Always Faster – Understanding Recoater Limitations When designing build layouts for metal additive manufacturing, it’s tempting to assume that packing as many parts as possible will automatically lead to faster, more efficient production. However, thi... Jan 7, 2026 Repeatability and Process Control
Unlocking Lightweight Performance with Lattice Infill Lightweighting is a central design goal in industries like aerospace, drones, and robotics, where reducing mass translates directly to better performance. In this case study, a drone arm previously ma... Jan 6, 2026 Advanced Structures & Lightweighting
The High Stakes of Undersized Escape Holes in Ceramic AM When working with ceramic-filled powders or other high-viscosity materials in additive manufacturing, small details make a massive difference, especially escape hole sizing. As the Scojet graphic emph... Dec 18, 2025
Thin-Wall Designs Without Compromise Lightweight doesn’t have to mean fragile. One of the greatest misconceptions in engineering is that thin walls automatically imply weakness. In metal additive manufacturing, that assumption is outdate... Dec 18, 2025
Add Relief Cuts to Reduce Thermal Stress Concentration In the world of metal 3D printing, thermal stress is an unavoidable consequence of localized heating and rapid cooling. As each layer fuses, internal stresses begin to build, often culminating in visi... Dec 18, 2025
Myth vs Fact: AM Can Outperform Machining for Complex Parts There’s a persistent myth in manufacturing that metal 3D printing is always more expensive than traditional machining. While this may hold true for simple, high-volume parts, the economics shift drast... Dec 18, 2025
Consolidating Brackets into One Printed Part One of the most transformative advantages of metal 3D printing is the ability to consolidate multiple components into a single structure. Traditional brackets often require multiple fasteners, welds, ... Dec 18, 2025
Designing for Powder Flow in Complex Channels In metal additive manufacturing, internal channels are often used for cooling, weight reduction, or fluid transport. However, many engineers overlook how critical powder flow is during the printing an... Dec 18, 2025 Design for Additive Manufacturing
Recycled Powder in Aerospace? Yes, With the Right Controls There’s a common myth in additive manufacturing that recycled powder is only suitable for prototypes or low-stakes applications. But when properly managed, recycled powder blends can meet even the str... Dec 11, 2025 Materials & Metal Powders
Thermal Mass Matters, Why Gradual Transitions Prevent Distortion One of the most common causes of distortion and cracking in metal additive manufacturing is sudden changes in wall thickness. When thin sections abruptly transition into thick areas, heat is absorbed ... Dec 11, 2025 Design for Additive Manufacturing