The landscape of industrial manufacturing is continuously evolving, with large-format additive manufacturing solutions gaining unprecedented traction. Among these innovative approaches, Directed Energy Deposition (DED) has emerged as a particularly dynamic and versatile technology, garnering significant interest across various sectors. While DED has notably seen extensive application in aerospace and defense, where precision, strength, and customized parts are paramount, its capabilities are now expanding into new territories. A prime example of this expansion is the recent announcement by AML3D, signaling its strategic entry into the United States utilities market through the significant sale of its advanced ARCEMY® X 3D printer to the Tennessee Valley Authority (TVA).

The Tennessee Valley Authority: Powering a Growing Region with Innovation

The Tennessee Valley Authority (TVA) stands as a monumental figure in American infrastructure. As a federally owned corporation, it holds the distinction of being the sixth-largest power supplier and the largest public utility in the United States. Its vast network serves a critical role in the Southeast, encompassing Tennessee, northern Alabama, northeastern Mississippi, southwestern Kentucky, and portions of northern Georgia, western North Carolina, and southwestern Virginia. This extensive service area provides power to a population exceeding nine million people, a demographic that, according to recent studies, is experiencing growth at a rate three times faster than the national average.

To meet the ever-increasing energy demands of such a rapidly expanding population, the TVA operates a remarkably diverse and expansive energy portfolio. As of 2023, its generation assets included four fossil plants, three nuclear plants, 29 hydro plants, one pumped storage hydroelectric plant, nine natural gas combustion turbine gas plants, eight natural gas combined cycle gas plants, one diesel generator site, and nine solar energy sites. This diverse array underscores the TVA’s commitment to ensuring reliable power while simultaneously exploring more sustainable and cost-effective energy production methods for the region. The continuous need for innovation and advancement is a core driver for the TVA, propelling it towards cutting-edge technologies like additive manufacturing.

A map of the area served by the TVA (photo credits: Beyond Plan B)

TVA’s Continuing Embrace of Additive Manufacturing

The TVA’s foray into additive manufacturing is not a recent development. The public power corporation has, in fact, been a pioneering adopter of this transformative technology for several years, recognizing its potential to enhance operational efficiency, reduce costs, and bolster supply chain resilience. Back in 2021, a significant milestone was achieved when 3D printed parts were successfully installed for the first time at the TVA’s Browns Ferry Nuclear Plant in Alabama, a collaborative effort with the Oak Ridge National Laboratory (ORNL). This initial venture demonstrated the viability and benefits of additive manufacturing for critical components within a nuclear power environment.

Building on this success, another notable ORNL project involved the creation and installation of 3D printed runners at the TVA’s Ocoee Dam in Tennessee. These applications highlighted the technology’s potential for both nuclear and hydroelectric power generation, showcasing its adaptability across different types of utility infrastructure. The acquisition of AML3D’s ARCEMY® X 3D printer now signifies not only the TVA’s sustained and deepening interest in additive manufacturing but, more specifically, its commitment to integrating large-format metal additive solutions into its core operations. This strategic investment is poised to further enhance the TVA’s capacity for rapid repair, on-demand part production, and the development of specialized components that are crucial for maintaining and upgrading its vast energy grid.

AML3D’s ARCEMY® X: Advanced Metal AM for Utility Applications

The ARCEMY® X 3D printer from AML3D is set to be a cornerstone of innovation at the TVA’s Muscle Shoals service facility in Alabama. This facility plays a vital role in providing advanced additive manufacturing capabilities to the TVA’s extensive power generation repair fleet. The selection of the ARCEMY® X underscores its suitability for the rigorous demands of the utilities sector, particularly for large and critical components.

At the heart of the ARCEMY® X lies AML3D’s patented WAM^® process, a sophisticated form of wire-arc Directed Energy Deposition (DED). WAM® is renowned for its efficiency, precision, and ability to produce high-quality metal parts rapidly. This process is particularly valuable for both complex repairs of existing components and the fabrication of entirely new, large-scale parts. The ARCEMY® X model, in particular, has been engineered to excel in printing extra-large components, boasting an impressive safe print area of 0.5 meters wide by 0.5 meters long, and an even larger maximum print envelope of 1.8 meters by 1.8 meters. This expansive build volume positions it as an ideal solution for manufacturing or repairing significant parts such as turbine components, structural elements for power plants, and custom tooling, which are often too large or complex for traditional manufacturing methods or smaller-format 3D printers.

The acquisition process for this cutting-edge machine was highly competitive. AML3D confirmed that the ARCEMY® X was chosen after a rigorous tender process, during which the TVA meticulously assessed various additive manufacturing options available in the market. This comprehensive evaluation underscores the ARCEMY® X’s superior capabilities and its alignment with the TVA’s specific operational needs and long-term strategic goals. The total contract, valued at $2.27 million, also includes a comprehensive two-year service and maintenance package, with an option for further extension. This robust support system ensures the longevity and optimal performance of the machine, guaranteeing that the TVA can maximize its investment. Final commissioning of the ARCEMY® X at the Muscle Shoals facility is anticipated to occur in the second half of 2025, marking a new chapter in the TVA’s journey towards advanced manufacturing.

The ARCEMY® X from AML3D (photo credits: AML3D)

AML3D’s US Scale-Up Strategy and Market Expansion

This landmark sale to the TVA perfectly aligns with AML3D’s ambitious US Scale Up strategy. This strategic initiative focuses on expanding the company’s footprint into burgeoning industry sectors across the United States, while simultaneously reinforcing its established presence in the defense sector. AML3D has already built a commendable track record, particularly through its successful engagements with the US Navy, where its additive manufacturing solutions have been instrumental in producing critical components for submarines. This proven expertise in high-stakes environments, where quality and reliability are non-negotiable, positions AML3D favorably for its expansion into new markets.

The company has expressed strong expectations for further growth and diversification, specifically targeting the utilities, aerospace, oil & gas, and maritime sectors within the country. These sectors share common requirements for large, durable, and custom-fabricated metal parts, areas where AML3D’s WAM® technology and ARCEMY® systems provide significant advantages. Sean Ebert, the CEO of AML3D, articulated the significance of this move, stating, “This entry into the US Utilities sector also supports our decision to further expand our US facilities, funded by the recent capital raising, to meet the continuing growth in demand and for our advanced manufacturing technology across the US.” This statement underscores the company’s commitment to scaling its operations to match the increasing demand for its innovative solutions, indicating a robust growth trajectory.

Pete Gourmas, President of AML3D US, further elaborated on the strategic importance of this new partnership and the company’s broader vision. He concluded, “It is very exciting to be working with the TVA and creating new growth opportunities in the Utilities sector to complement our continuing success supplying the US Navy’s Submarine Industrial base. AML3D’s strategy for growth in the US has always included expanding into new sectors […] I’m particularly pleased to earn this TVA order since it was a competitive solicitation, and we believe we have the best offering in large format wire arc systems in the world. Expanding into the US utilities sector is just the beginning as there are significant opportunities to continue to expand our technology into the US Aerospace, Oil & Gas and Marine sectors as well. We are just getting started.” Gourmas’s remarks highlight AML3D’s confidence in its proprietary technology, its ability to secure highly competitive contracts, and its long-term strategy for market penetration and leadership across multiple critical US industries.

This collaboration between AML3D and the TVA represents a significant step forward not just for the involved entities, but for the entire industrial additive manufacturing landscape. It exemplifies how advanced technologies can be leveraged to address the complex challenges of modern infrastructure, ensuring efficiency, sustainability, and resilience for years to come. The integration of large-format metal 3D printing into power generation operations paves the way for a more agile and innovative approach to maintaining and upgrading essential utility services across the nation.