RAPID + TCT 2024 Spotlight: 6K Additive Unveils Sustainable Metal AM Innovations and Future Vision

As the highly anticipated RAPID + TCT 2024 event draws near, the excitement surrounding its extensive lineup of exhibitors is palpable. With over 400 innovative companies expected to attend, navigating the vast exhibition floor can be a challenge. To provide a clearer perspective on what attendees can anticipate this year, we had the distinct pleasure of sitting down with representatives from some of the leading organizations. Our journey begins with 6K Additive, a trailblazer in advanced material manufacturing. A consistent presence at RAPID + TCT since its inception in 2019, 6K Additive continues to push the boundaries of metal additive manufacturing. We recently had the opportunity to speak with Frank Roberts, the esteemed president of 6K Additive, to delve deeper into the company’s groundbreaking work and understand why this event holds such significant importance for the broader additive manufacturing community across the United States.

3DN: Could you introduce yourself and 6K Additive?

My name is Frank Roberts, and I am the President of 6K Additive. My professional foundation is rooted in metallurgical engineering, a discipline I pursued academically. The initial phase of my career, spanning many years, was dedicated to mill products, where I specialized in supporting the production of critical titanium and nickel-based alloys primarily for the demanding aerospace industry. This experience provided me with an intimate understanding of high-performance materials and stringent quality requirements. Subsequently, I transitioned from a large, publicly traded corporation to a smaller enterprise, which I eventually had the opportunity to acquire and build.

Our operations were established and grew significantly here in Pittsburgh. It was during this period that our paths converged with the team at 6K, and we were first introduced to their truly revolutionary Microwave-Based Plasma Technology, known as UniMelt. This innovative approach captivated us, leading to the strategic decision to merge our entities, forming what is now recognized as 6K Additive. We are a premier metal alloy producer, distinguished by our unique method for creating highly spherical powders specifically tailored for metal additive manufacturing applications. Following our pivotal deal with 6K in 2019, we embarked on the development and construction of a state-of-the-art powder manufacturing facility. Our process is fundamentally distinct from conventional atomization techniques, whether plasma or gas-based. Instead of atomization, our core innovation lies in spheroidization, a process that redefines efficiency and sustainability in powder production.

What this spheroidization process means for the industry is profound: we are actively taking revert materials, essentially high-value scrap or by-products, from both the subtractive and additive manufacturing sectors. These materials, which might otherwise be downcycled or considered waste, are then meticulously put through a sophisticated vetting and sizing operation. This typically involves reducing the material to a precise particulate size. We engineer a bespoke feedstock that not only possesses the exact elemental chemistry required for a particular material but also features the ideal volume and morphology of particulate for applications like Laser Powder Bed Fusion (LPBF), often targeting the critical 15-35 micron range. These initial sizing and preparation operations are conducted with an emphasis on low cost and high efficiency. While the material is now correctly sized and chemically balanced, its shape remains irregular. This is where the UniMelt microwave-plasma technology becomes instrumental. We leverage this advanced plasma to spheroidize the irregular particulate into exceptionally spherical powders. These powders exhibit superior flowability, packing density, and reduced porosity, ensuring high repeatability and the precise characteristics essential for demanding LPBF applications, ultimately leading to higher quality and more consistent end parts.

These superior characteristics translate directly into enhanced performance for LPBF applications, enabling manufacturers to achieve unprecedented part quality and reliability, while simultaneously embracing a more sustainable supply chain.

3DN: Why is it important to be at RAPID + TCT?

From our strategic perspective at 6K Additive, RAPID + TCT undeniably stands as the premier and most vital venue for additive manufacturing in the United States. Our company has been a dedicated participant at this event since its formation. Even in our early days, with a considerably smaller footprint, we recognized that this was the quintessential gathering place for the entire AM ecosystem in the US. The show offers an unparalleled platform for engagement and growth.

Expanding on this, particularly from the vantage point of metal additive manufacturing and, more specifically, metal powder producers, the market is experiencing truly significant and rapid expansion. RAPID + TCT offers a unique, one-stop-shop opportunity to deeply engage with the industry. It allows us to connect not only with our cherished current customer base, strengthening existing partnerships, but also to identify and forge relationships with new prospects actively seeking advanced materials and innovative suppliers. Furthermore, the event is instrumental in nurturing our vital relationships with Original Equipment Manufacturers (OEMs). Year after year, the turnout is exceptional, attracting precisely the right caliber of individuals – decision-makers, technical experts, and commercial leaders – necessary for maintaining and expanding these critical contacts.

As 6K Additive continues its trajectory of scaling up operations and deepening our engagement with the broader market, the necessity for more frequent and meaningful touch points with customers becomes paramount. This emphasis on customer interaction is a significant topic across the additive manufacturing industry, especially as metal AM transitions towards widespread commercialization and accelerated adoption across various sectors. This direct engagement is particularly crucial in highly regulated and demanding fields such as medical, where you consistently observe the highest level of producers and innovators attending. Beyond medical, we encounter end-users from a diverse array of sectors, including aerospace, defense, critical medical implants and devices, energy (oil & gas), and numerous other high-value applications, all converging at RAPID + TCT to explore the latest advancements.

What we consistently observe and value at RAPID + TCT is the unparalleled environment it creates for fostering more strategic and collaborative partnership conversations. The show attracts not only C-Suite executives and leadership teams but also commercial teams, active buyers, and innovative sellers from across the entire additive manufacturing value chain. This unique convergence allows everyone to effectively connect, exchange ideas, and explore synergistic opportunities. Moreover, as a key material supplier, the constant stream of commercial and technical discussions happening everywhere within the exhibition halls provides us with invaluable real-time market intelligence, enabling us to clearly identify how we can better serve the evolving needs of the market and tailor our offerings accordingly.

3DN: What is 6K Additive showcasing this year?

From a product innovation standpoint, our commitment to promoting our established high-performance materials – including nickel, stainless steel, and copper alloys – remains steadfast. These “classics” continue to be foundational to numerous additive manufacturing applications. However, a particularly exciting showcase this year will undoubtedly be our advanced refractory alloys. We possess a truly unique capability in this domain, which we are currently working diligently to scale up to meet growing industrial demand. A prime example is C103, a specialized niobium-based alloy that sees extensive use in extremely demanding applications, particularly within the realm of hypersonic aerospace technologies. We are observing a significant increase in companies actively seeking to understand and successfully work with these more difficult and high-performance materials. Our sustainable processing method is uniquely tailored to handle such complex alloys, offering a reliable and environmentally conscious solution.

Beyond specific material offerings, the other central pillar of our showcase, and indeed our core identity as a company, is sustainability in general. At 6K Additive, our manufacturing philosophy is intrinsically tied to circular economy principles: nothing in our product creation process originates directly from virgin ore mined from the earth, and critically, nothing ultimately ends up as waste in landfills. We have engineered our process to be entirely independent of traditional mining operations for raw material sourcing. Our overarching goal is to achieve zero waste generation throughout our production lifecycle. This powerful message of sustainability will be prominently displayed and emphasized at RAPID + TCT. We are eager to demonstrate to our potential and existing customers how partnering with 6K Additive allows them to significantly lower their carbon footprints by utilizing our sustainably produced materials. Furthermore, we will be highlighting our recent successes in material qualification, particularly our achievements with major power producers, which underscores the reliability and industrial readiness of our advanced materials and processes.

3DN: What do you expect from the show?

Considering our strategic position within the additive manufacturing landscape, our primary objectives for RAPID + TCT this year are multifaceted. At the forefront is the expansion and strengthening of our existing relationships, building upon the strong foundations we’ve established over the years. Equally important is the active development of new partnerships and connections. As I’ve highlighted previously, this dual focus on nurturing current ties and forging new ones is precisely what consistently brings 6K Additive back to RAPID + TCT year after year.

It is at this premier event that we gain an invaluable platform to not only showcase our latest innovative materials but also to clearly demonstrate how these advanced solutions can be effectively utilized to meet the increasingly stringent demands of various industries. We are genuinely looking forward to the dynamic interactions: meeting new individuals, engaging with potential collaborators, and, most importantly, cultivating deeper, more meaningful relationships that extend beyond the transactional. Ultimately, our vision is to foster greater collaboration across the entire industry, recognizing that collective effort is essential for advancing the capabilities and widespread adoption of additive manufacturing.

3DN: Any last words for our readers?

As the additive manufacturing industry continues its relentless trajectory of growth, transformation, and evolution, new opportunities are constantly emerging, presenting both exciting prospects and complex challenges. In this dynamic environment, RAPID + TCT unequivocally stands as the best and most impactful venue in the US to immerse oneself, actively participate, and continue to collectively further this vital evolution and chart the path forward for the entire industry!

For 6K Additive, our driving force and where we are truly moving the needle is in the realm of sustainability. However, for sustainability initiatives to be genuinely successful and widely adopted, they must seamlessly integrate with uncompromising quality standards and demonstrate the capability to produce at industrial scale. Moreover, we believe that collaboration has become more critical than ever before. There’s an urgent need for all stakeholders in the additive manufacturing ecosystem to work together more closely. This collaborative spirit is essential, whether it’s for developing a wider range of AM-compatible materials, enhancing material specifications to meet stricter performance requirements, or optimizing processes for greater efficiency. This is precisely where we, as material providers, along with the OEMs, and crucially, the end-users, need to connect the dots and establish robust communication channels. RAPID + TCT provides the absolute best environment for these vital connections and collaborations to flourish. If you haven’t already secured your spot, be sure to get your complimentary Expo Pass HERE.

Will you be seeing 6K Additive at RAPID + TCT 2024? We’d love to hear your thoughts! Let us know in a comment below or connect with us on our LinkedIn, Facebook, and Twitter pages! And don’t forget to sign up for our free weekly newsletter here for the very latest 3D printing news delivered straight to your inbox! You can also find all our insightful videos and interviews on our YouTube channel.

*Cover Photo Credits: 6K Additive