Renishaw, a global engineering technology firm with operations in over 30 countries, has partnered with Cookson Industrial, a UK-based specialist in precious metal additive manufacturing (AM), to revolutionize the production of platinum rhodium components through additive manufacturing. The collaboration aims to overcome the challenges associated with the high cost of platinum rhodium, making it a more economically viable option for various industries, including aerospace and catalysis.

Platinum rhodium is a crucial material for applications requiring high-temperature resistance, such as in the production of glass fibers. Its ability to withstand extreme temperatures and harsh conditions makes it indispensable in certain industrial processes. Cookson Industrial sought to utilize platinum rhodium in 3D printing an extrusion mold for glass fiber manufacturing. However, the exorbitant cost of this material, priced at approximately £80,000 per kilogram, necessitated efficient material usage to minimize wastage and expenses.

To address this issue, Cookson Industrial integrated Renishaw’s RenAM 500S Flex, a part of the RenAM 500 series of laser powder bed fusion (LPBF) systems, into their production process. This advanced system offers enhanced powder management capabilities, enabling efficient powder retrieval and reuse. By leveraging targeted system modifications, the partnership successfully reduced powder wastage from 1.5% to under 0.5%, significantly optimizing the utilization of precious platinum rhodium powder.

The collaboration between Renishaw and Cookson Industrial exemplifies how innovative additive manufacturing technologies can drive cost-effective production of high-value materials. The tailored solutions provided by Renishaw’s team, including the redesign of key components to enhance powder retrieval efficiency, resulted in substantial cost savings for Cookson Industrial. This achievement not only made the commercial production of platinum rhodium components feasible but also laid the groundwork for exploring new applications in diverse industries.

Looking ahead, Cookson Industrial plans to explore additional applications for platinum rhodium, particularly in catalysts and aerospace engine nozzles. The success of this collaboration underscores Renishaw’s commitment to supporting its customers in adopting additive manufacturing technologies, especially when working with novel materials. By facilitating the efficient utilization of precious metals like platinum rhodium, Renishaw and Cookson Industrial are paving the way for enhanced manufacturing capabilities and innovative industrial applications.

In the broader context of industrial additive manufacturing, the demand for high-performance metal powders is on the rise. Companies like 3D Lab are introducing advanced solutions for custom powder production and quality control, catering to the evolving needs of the industry. Additionally, collaborations between organizations like NASA and various material developers highlight the strategic importance of developing specialized powders for aerospace and space applications, further driving innovation in the additive manufacturing sector.

The partnership between Renishaw and Cookson Industrial serves as a testament to the transformative potential of additive manufacturing in enhancing the viability of producing precious metal components. By leveraging cutting-edge technologies and collaborative efforts, the industry is poised to unlock new possibilities in material utilization and application development, shaping the future of manufacturing across diverse sectors.