Lab22: Pioneering Metal Additive Manufacturing in Australia

Lab22, the specialist facility for metal additive manufacturing operated by the Commonwealth Scientific and Industrial Research Organisation (CSIRO), is at the forefront of advancing Australia's industrial innovation. Located at CSIRO's Clayton site in Melbourne, Lab22 has been integral in introducing and promoting metal additive manufacturing—a process commonly referred to as 3D printing—across various Australian industries for the past decade.

Established with the aim of enabling companies to explore and implement additive manufacturing technologies, Lab22 has seen a notable increase in interest and adoption of these advanced manufacturing techniques among local businesses. According to Dr. Daniel East, Group Leader for Advanced Manufacturing and Metals at CSIRO, "Lab22 serves as a critical hub for businesses seeking to integrate additive manufacturing into their operations, allowing them to test the viability of new processes and materials."

The significance of Lab22's initiatives is underscored by a recent $45 million partnership involving universities and CSIRO, which is part of the Australian Government’s Trailblazer Universities Program. This collaboration is designed to enhance the capabilities of additive manufacturing in Australia, reflecting the growing demand for innovative manufacturing solutions. As industries increasingly recognize the potential of additive manufacturing, CSIRO has invested in next-generation equipment and optimized feedstock materials, thereby broadening the scope of what can be achieved through this technology.

Historically, Australian companies have approached additive manufacturing with caution, often hesitant to adopt new materials alongside new processes. Traditionally, alloys were developed to optimize properties for conventional manufacturing methods such as rolling or forging, which do not align with the rapid cooling rates characteristic of additive manufacturing. However, as the technology matures, there is a discernible shift towards the demand for alloys specifically engineered for additive manufacturing conditions.

To meet this demand, Lab22 has made significant equipment investments, including the Tekna Tek15 spheroidiser and the MarkForged PX100 binder jet 3D printer, both of which are unique within Australia. The Tekna Tek15 transforms non-spherical powders into spherical powders, optimized for additive manufacturing, while the MarkForged PX100 enables the production of intricate components from these powders. This innovative approach not only enhances the precision of the manufacturing process but also reduces costs associated with traditional manufacturing methods.

Furthermore, advancements in multi-material systems at Lab22 open new avenues for complex geometrical designs. In partnership with the iLaunch Trailblazer initiative, CSIRO has introduced a Selective Laser Melting (SLM) multi-material laser powder bed system, which allows for the fabrication of complex geometries using distinct alloys. Initial trials have demonstrated the potential for high-temperature applications, integrating copper alloy cooling channels with steel alloy components for improved mechanical strength.

In addition to these advancements, CSIRO is actively engaged in developing a robotic laser wire/powder deposition system, which is the largest additive manufacturing cell in their facilities. This system is designed for large-format 3D printing and prototyping, accommodating significant build volumes while optimizing the heat input to enhance the microstructure of the deposited materials.

As Australia continues to embrace additive manufacturing, Lab22 stands poised to drive its evolution into a mainstream industrial process. Through ongoing collaboration with the Trailblazer programs and the forthcoming Additive Manufacturing Cooperative Research Centre, CSIRO aims to provide industries with the necessary tools and expertise to harness the full potential of additive manufacturing. Interested parties are encouraged to connect with CSIRO or engage with these organizations for access to facilities and additional resources, as Australia positions itself as a leader in the field of advanced manufacturing.

For more information about CSIRO’s Lab22 and its initiatives, visit https://www.csiro.au/en/research/technology-space/it/Lab22.