Additive Industries introduces MetalFab 420K for high-demand metal AM production

Additive Industries has unveiled its new flagship metal additive manufacturing system, the MetalFab 420K. The system combines four 1kW lasers with a modular and automated design, aiming to deliver higher productivity and material quality for demanding applications in sectors such as aerospace, space, automotive and high-tech manufacturing.

The MetalFab 420K is built to push the boundaries of laser powder bed fusion (LPBF) technology. Each of the four lasers can access the full 420 x 420 x 400 mm build volume, allowing for faster production without compromising on precision. A highly optimised gas flow system ensures uniformity and quality across the entire powder bed, supporting higher scan speeds and improved melt pool stability.

Technological advancements for industrial-scale metal AM

The machine offers a variable beam diameter ranging from 100 to 500 micrometres, enabling users to fine-tune parameters for specific materials and applications. Its open architecture provides full control over process development, allowing manufacturers to optimise settings for productivity or experiment with difficult-to-process alloys. Automated laser calibration and in-build laser-to-laser alignment further improve reliability and consistency between jobs.

In addition, the system features advanced oxygen and humidity monitoring to slow powder ageing and enhance part integrity. A redesigned permanent filter reduces maintenance requirements and improves waste-handling efficiency. Operator safety and material quality are safeguarded through fully enclosed and automated powder handling, sieving and transport.

Modular design for scalable production

The modular architecture of the MetalFab 420K enables users to expand capacity on site. Depending on configuration, up to eight jobs can run automatically without operator intervention. The system can also host up to three different materials simultaneously by installing multiple additive manufacturing cores in series, giving manufacturers increased flexibility for complex production workflows.

“Our objective is to provide market-leading quality and productivity for additive manufacturing users,” said Mark Massey, CEO of Additive Industries. “The MetalFab 420K is built on proven technology and designed around the needs of our most demanding customers, allowing them to scale their operations while maintaining uncompromised quality.”