Materials Science & Technology 2005, September 25-28, Pittsburgh, USA Metal Printing Process: A Rapid Manufacturing Process Based on Xerography using Metal Powders Casper van der Eijk, Olav Åsebø, Øyvind Kolnes, Terje Mugaas, Roald Karlsen, Rune Skjevdal and Klas Boivie SINTEF, Alfred Getz vei 2, 7465 Trondheim, Norway, casper.eijk@sintef.no Keywords: Rapid Manufacturing, Near-Net Shape Processes, Metal Printing Process Abstract A new method of rapid manufacturing called the Metal Printing Process (MPP) is under development at SINTEF in Norway. This method is using xerography to build objects using powders of metals and ceramics in a layered manner. Each layer is transferred from the photoreceptor onto a punch which is used to press the new layer onto the growing object in a die. The new layers are subsequently consolidated. To build object with a complex shape, a support powder must be used. This support powder must behave similar to the building powder during layer printing, but needs to behave differently (i.e. not sinter) when the part is sintered. By varying the composition of the layers in the z- direction, graded materials can be made. Introduction There is an industrial trend towards production methods that reduce time consuming and costly machining operations. The purpose of the Metal Printing Process (MPP) research program is to develop a new and revolutionary production technology to meet this challenge. The MPP is a process that builds components ready for use directly from metal (and ceramic) powders using layer manufacturing principles. The MPP research program aims to develop, build and demonstrate a Metal Printing prototype machine with industrial functionality[1]. Metal Printing Process overview A potential solution for part-producing industry for on-demand, cost-effective manufacture, re-supply, or low volume production of functional objects is the emerging technology arena known as Rapid Manufacturing. Rapid Manufacturing technologies offer a significant reduction of time and cost to bring new products to the market. The SINTEF Metal Printing Process is aimed at developing the equivalent of a high-speed photocopier that produces three-dimensional objects from powder material. This technique is based upon the commercially proven technology of photocopiers that use photo-masking and electrostatic attraction. The MPP technique uses the same fundamental functions to build solid objects on a layer-by-layer basis[2,3].