Mitsubishi Electric Corporation
Kumamoto University
TOHO KINZOKU CO., LTD.
Japan Aerospace Exploration Agency

Industry’s First Technology to Use Magnesium Alloys in Wire-Laser Metal
3D Printer Developed by Multi-sector Consortium in Japan
Mitsubishi Electric, Kumamoto University, TOHO KINZOKU and JAXA pave the way for producing
lightweight, fuel-saving industrial components with highly processable magnesium alloys

Magnesium-alloy additive manufacturing system

Sample of magnesium alloy for additive manufacturing

TOKYO, June 13, 2024 – Mitsubishi Electric Corporation (TOKYO: 6503), Magnesium Research Center(MRC) of Kumamoto University, TOHO KINZOKU CO., LTD., and the Japan Aerospace Exploration Agency(JAXA) announced today the 3D printing industry’s first1 high-precision additive manufacturing (AM)technology for using magnesium alloys in a wire-laser metal 3D printer via the directed energy deposition(DED)2 method, marking a significant leap forward in industrial manufacturing. Unlocking the potential toprocess magnesium alloys with unparalleled precision and complexity will pave the way for rocket, automobile,
aircraft, etc. components that are lighter and stronger than those made of iron or aluminum, leading to
improved fuel efficiency and, in the case of rockets, reduced production costs. In addition, the envisioned
production processes based on a wire-laser metal 3D printer will be more energy efficient and generate fewer
greenhouse gas emissions compared to conventional processes, promising to deliver low-impact solutions forincreased sustainability.
Since September 2022, the consortium members have been conducting joint research (Research on Laser Wire
DED Method AM Process Technology Using Magnesium Alloy Wire) under the framework of JAXA’s
Innovative Future Space Transport System Research and Development Program,3 working to reduce theweight of rockets and thereby drastically cut costs. In addition to rockets, the need for weight reduction has
According to Mitsubishi Electric research as of June 13, 2024
AM process that uses thermal energy to fuse materials as they are being deposited3
Innovative Future Space Transport System Research and Development Program.
https://www.kenkai.jaxa.jp/eng/research/kakushinyusou/kakushinyusou.html
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increased in recent years due to factors including the shift to electric vehicles and the growing demand forcommercial aircraft, so magnesium alloys are attracting attention in many fields. But magnesium alloys are
typically processed by die casting,4 making it difficult to create structures with hollow interiors. Also themainstream powder bed fusion (PBF)5 method for AM, which uses heat to selectively melt metal powder, canlead to degradation through oxidation or dust explosions, posing a problem for safe manufacturing.
In response, the consortium combined Mitsubishi Electric's metal 3D printer, which uses the wire-laser DED
method and metal wire instead of metal powder as a material, with a highly nonflammable KUMADAI heatresistant magnesium alloy6 developed by MRC. In tests, Mitsubishi Electric repeated the molding process with
the KUMADAI heat-resistant magnesium alloy produced by TOHO KINZOKU using advanced wire drawing
technology. The result is a new technology that uses a magnesium-alloy wire as an AM material and precise
temperature control to prevent combustion.
Based on JAXA’s evaluation of AM production samples produced with this new technology, it is estimatedthat some rocket parts could be made up to about 20% lighter than those with traditional aluminum alloy
structures.
Furthermore, it is believed that the same process could be widely applied to other fields where weight reductionis also required, including various transportation equipment and robotic components. Accordingly, further
research and development targeting applications in various industrial fields will be conducted in parallel with
Mitsubishi Electric’s work to commercialize the technology in a wire-laser DED metal 3D printer by around2029.
Product Features
1)

AM of magnesium-alloy wire combines high workability and strength- MRC studied many KUMADAI heat-resistant magnesium alloys to find a composition for AM that isflame-resistant even in wire form.
- TOHO KINZOKU established a technology for producing wire of any diameter and length for AM, andfabricated prototype wires that were extensively tested by Mitsubishi Electric, resulting in an optimum wire
thickness and wire drawing process.

2)

High-precision AM technology uses nonflammable magnesium-alloy wire
- Mitsubishi Electric has developed a technology for its wire laser DED metal 3D printer that precisely
controls laser power and wire speed using computer numerical control (CNC) to keep the processing
area at a constant temperature. This enables magnesium alloys with a width of 3mm to be processed
into any shape with high precision and without burning.
- Unlike die casting, no mold is required, eliminating the cost of changing and replacing molds.

Metal casting process that forces molten metal under high pressure into a mold cavity
AM process where a thermal energy source, such as a laser or electron beam, selectively fuses regions of a powder bed to form asolid part
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Magnesium alloy developed by MRC that achieves superior strength and heat resistance
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3)

Magnesium-alloy AM structure will lead to lighter rocket parts- AM production samples achieve a high tensile strength of about 250 megapascals (MPa) at room
temperature and about 220MPa at high temperatures around 200 degrees, equal to or better thanconventional methods. Also, the samples have been shown to be heat resistant and nonflammable.
- In evaluating the samples’ applicability as rocket materials compared to conventional materials, JAXA
found that the weight of rocket shell structures and aerodynamic control fins could be significantly
reduced by up to 20%.

4)

AM processing does not generate greenhouse gases, supporting sustainability- Magnesium alloys are lighter and stronger than aluminum and iron, so their use in automotive andaircraft components will contribute to greater fuel efficiency.
- Compared to machining from ingots,7 minimized material waste will help improve energy efficiency
in processing as well as conserve materials.
- The technology eliminates the use of sulfur hexafluoride (SF6), a greenhouse gas with a high global
warming potential that is conventionally used as a shielding gas8 for magnesium-alloy casting, helping
to significantly reduce greenhouse gas emissions.

Purpose of the Joint Research
The aim of this joint research is to commercialize a new alloy wire material for metal AM that has superior
strength compared to existing alloy wires, in order to realize drastic cost reductions of rocket structures throughthe weight reduction of large structures such as propellant tanks. High-strength wires suitable for metal AM
can be applied not only to space transportation, but also to various transportation equipment and robot
components where weight reduction is required, as well as other ground structures.

Responsibilities of Each Consortium Member
Mitsubishi Electric
MRC
TOHO KINZOKUJAXADevelopment of AM technology using magnesium alloys and verification ofmaterial properties of AM production samples
Selection of magnesium-alloy composition for AM
Development of manufacturing method for magnesium-alloy wire
Evaluation of magnesium-alloy AM production samples to estimate potential
impact on rocket weight reduction
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Block of pure material, often metal, that is cast into a shape for further processing
Gas used to prevent molten magnesium from igniting when exposed to air

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