Students build aerospace 3D printer that fuses two metals at once

A team of Swiss bachelor students at ETH Zurich has developed an innovative 3D metal printer, named RAPTURE, that significantly advances aerospace manufacturing by enabling high-speed, multi-material printing. Unlike traditional 3D printers that operate in a stop-start manner, this prototype uses a rotating laser powder bed fusion (LPBF) system to continuously deposit and fuse metal powders. This design allows the simultaneous fusion of two different metals—such as a copper core with a nickel-alloy exterior—in a single seamless step, which is particularly suited for producing complex aerospace components like rocket nozzles and turbine parts with large diameters and thin walls. The rotating platform reduces production time by over two-thirds compared to conventional methods. The RAPTURE machine also incorporates a novel gas flow system that directs inert gas across the fusion zone to prevent oxidation and continuously removes by-products like soot and spatter, resulting in cleaner builds and higher part quality. This feature was found critical to the success of the printing process. Initially created to support