Xerox ElemX: Revolutionizing Industrial Metal 3D Printing with Liquid Metal Technology

Xerox, a name synonymous with innovation in document technology, has made a decisive and impactful entry into the world of additive manufacturing. This strategic move began with the significant acquisition of Vader Systems, a pioneering startup specializing in liquid metal 3D printing. This acquisition was a clear declaration of Xerox’s ambition to tap into the immense potential of the 3D printing market, armed with a technology poised to redefine industrial production. A year after this pivotal announcement, Xerox proudly unveiled its inaugural liquid metal 3D printer: the ElemX. This groundbreaking machine employs a unique process, utilizing metal, specifically aluminium, wires that are meticulously melted and deposited layer by layer to construct the final part. The ElemX is engineered to address the critical needs of demanding sectors, including aerospace, automotive, marine, and the oil & gas industries, promising enhanced efficiency, safety, and supply chain resilience. Demonstrating its immediate relevance and transformative potential, the Naval Postgraduate School (NPS) in California has already commissioned an ElemX machine, integrating it into a new collaborative research project aimed at exploring and expanding the applications of 3D printing for the U.S. Navy.

For years, the majority of metal additive manufacturing processes have predominantly relied on metal powders to design and fabricate parts of varying complexity. While effective, these powder-based materials introduce a range of risks, posing significant concerns for both user health and operational safety. Institutions like the INRS have published comprehensive reports detailing these potential hazards, which include chemical exposure, the risk of explosion, and fire. The fine particulate nature of metal powders can lead to respiratory issues if inhaled, and their inherent flammability and explosive potential under certain conditions necessitate rigorous safety protocols and specialized infrastructure, increasing operational costs and complexity. Recognizing these inherent challenges, Xerox strategically opted for a machine that bypasses metal powder entirely, placing its bets on a cleaner, safer, and more efficient wire-based system. The result is the ElemX, an impressive piece of engineering measuring 2.7 meters wide by 2.1 meters high, designed to integrate seamlessly into various industrial environments. The Naval Postgraduate School (NPS) in California, a leading institution for naval officers, was among the first to receive the ElemX, establishing a vital collaborative research project with Xerox. This partnership will see the NPS leverage the ElemX to pioneer new capabilities and applications for the Navy and Marine Corps, exploring how liquid metal additive manufacturing can enhance readiness and logistical flexibility.

The ElemX’s build plate, showcasing the liquid metal deposition process. (Photo Credit : Xerox)

The Xerox ElemX: A Paradigm Shift with Liquid Metal 3D Printing Process

At the heart of the Xerox ElemX lies its revolutionary Liquid Metal process, which represents a significant departure from traditional additive manufacturing techniques. This innovative method begins with a readily available metal wire, specifically aluminium in its current iteration, which is supplied on a coil. The wire is fed precisely into a specialized tank, where it is heated to an impressive temperature exceeding 800°C. At this temperature, the metal melts into a liquid state. What truly sets the ElemX apart is how this liquid metal is then utilized: controlled droplets are formed and precisely projected onto the build tray using a sophisticated magnetic field. This magnetic propulsion system ensures unparalleled accuracy and speed, enabling the machine to deposit up to an astonishing 1,000 drops per second. This rapid deposition rate translates directly into significantly faster manufacturing times compared to many powder-based solutions. Furthermore, the ElemX’s process inherently reduces the need for extensive and costly post-treatment steps, which are often a bottleneck in traditional metal 3D printing workflows, thus streamlining the entire production cycle. While the exact maximum print volume of the machine remains undisclosed, it is understood to be capable of producing industrial-grade parts measuring up to approximately 300 x 300 x 127 mm. This build envelope makes it suitable for a wide array of applications, from intricate prototypes to robust end-use parts, further cementing its value in advanced manufacturing settings.

The Naval Postgraduate School (NPS) holds the distinction of being the very first institution to deploy the ElemX, underscoring the machine’s strategic importance. As its name implies, the NPS is a prestigious graduate school for naval officers in the United States, focused on advanced education and research critical to national defense. The decision to host the ElemX on its premises reflects a proactive approach to exploring the revolutionary potential of liquid metal 3D printing. The NPS aims to leverage the ElemX for a myriad of critical applications, including the rapid design and production of spare parts for various naval vessels and submarines, as well as for specialized tooling work. This research, particularly its focus on liquid 3D printing processes, holds the potential to dramatically transform the logistical landscape and supply chain resilience for military forces, especially those deployed forward. By enabling the on-demand production of parts closer to the point of need, it can drastically reduce lead times, minimize reliance on vulnerable global supply chains, and enhance operational readiness. Tali Rosman, Xerox Vice President and General Manager for 3D Printing, aptly articulated this vision: “Global supply chains leave industries like aerospace, automotive, heavy equipment, and oil and gas vulnerable to external risks. Our goal is to integrate localized 3D printing into their operations, and the real-time feedback from NPS gives us actionable data to continuously improve the ElemX.” This statement highlights Xerox’s commitment not only to commercializing advanced technology but also to fostering critical partnerships that drive continuous innovation and real-world impact across diverse industrial sectors.

Examples of robust parts printed with the Xerox ElemX liquid metal 3D printer. (Photo Credit : Xerox)

For the NPS, the Xerox ElemX machine presents a particularly compelling solution due to its primary material: aluminum. This choice is highly significant, especially within the context of a marine environment. Aluminum is renowned for its inherent resistance to corrosion and oxidation, properties that are absolutely critical for components exposed to saltwater and harsh weather conditions at sea. Beyond its environmental resilience, aluminum is also a cost-effective material, offering an excellent strength-to-weight ratio, which is vital for reducing overall vessel weight while maintaining structural integrity. Moreover, it possesses the durability and robust mechanical properties required to withstand the rigorous demands of naval operational duties. While the long-term vision includes the possibility of deploying 3D printers directly on board ships, the NPS teams are currently engaged in extensive research and testing to validate this capability. These crucial tests involve evaluating the technology’s ability to endure extreme conditions such as vibrations, jolts, and other dynamic stresses that are an inevitable part of a sea voyage. Ensuring the printer’s reliability and the integrity of its printed parts under such challenging circumstances is paramount before shipboard integration. Ann Rondeau, retired Vice President of the NPS, powerfully encapsulated the significance of this collaboration: “This collaborative research effort with Xerox and the use of their 3D printing innovations is a great example of how NPS uniquely prepares our military students to examine novel approaches to create, make, prototype and manufacture capability wherever they are. From the age of sail to the nuclear era, sailors have been fixing things at sea so they can complete the mission. This partnership is about the strategic ability of the Navy to have sailors on ships with the capability through creativity and technology to advance their operations at sea. Through collaboration, NPS and Xerox are helping build a Navy for the 21st Century.” This statement underscores the profound impact of this partnership, not just on logistical improvements but on empowering naval personnel with cutting-edge manufacturing capabilities that define modern naval strategy. To gain a deeper understanding of this transformative technology, be sure to check out the insightful video below illustrating Xerox’s ElemX in action.

The Xerox ElemX represents a significant leap forward in metal additive manufacturing, offering a compelling alternative to powder-based systems with its focus on safety, speed, and efficiency. Its ability to create robust aluminum parts on-demand, combined with its strategic partnership with the Naval Postgraduate School, highlights its potential to revolutionize supply chains and empower industries with localized production capabilities. You can find out more about the ElemX and Xerox’s transformative partnership with NPS here. What are your thoughts on the Xerox ElemX? Do you believe liquid 3D printing is poised to overtake traditional powder-based processes as the preferred method for metal additive manufacturing in industrial applications? Let us know your insights in a comment below or join the conversation on our Facebook and Twitter pages! For the latest breaking news and developments in the world of 3D printing, remember to sign up for our free weekly Newsletter here, delivering fresh updates straight to your inbox!