NCAME partners with Blue Origin to improve copper printability
Published: Mar 18, 2025 11:00 AM
By Jeremy Henderson
When it comes to overcoming the challenges of 3D printing with copper, Blue Origin has decided to work a little orange into their research.
The space technology company is the latest entry on the list of high-tech heavy hitters partnering with Auburn University's National Center for Additive Manufacturing Excellence (NCAME), an international leader in materials characterization and modeling crucial to the structural integrity necessary for additive manufacturing (AM) adoption — and to Blue Origin's future plans in orbit.
"Blue Origin recently donated two EOS M290s to NCAME to assist in improving the utility of copper in additive manufacturing," said NCAME director Nima Shamsaei, the Philpott-WestPoint Stevens Distinguished Professor of mechanical engineering. "Copper's high reflectivity presents challenges for traditional laser-based 3D printing systems to effectively melt and fuse the powder, as much of the laser energy is reflected."
EOS M290 printers are among the best suited to meet those challenges, among others.
"Copper also has high thermal conductivity, which makes melting even more inefficient,” said NCAME research scientist Jonathan Pegues. “Once it finally melts, absorptivity increases and leads to inconsistent melt pool behavior and potential defects in the printed part. Specialized laser systems that couple better with copper are often needed to overcome these challenges, but certain alloys like GRCop-42 have proven to be printable with standard IRF lasers, like those integrated in the EOS M290."
"We already had two EO2 M290s," Shamsaei said, "but these new additions will allow us to expedite the sort of applied research that can support Blue Origin’s needs for this alloy."
In January, Blue Origin successfully launched its first orbital launch vehicle, New Glenn, from Cape Canaveral Space Force Station's Launch Complex. It recently announced that the upcoming 11th human flight of New Shepard, its reusable, suborbital rocket system built for human flight, will feature an all-female crew that includes, among former NASA scientists and pop superstar Katy Perry.
"Blue Origin is obviously one of the main companies on the frontlines of exploring the final frontier," Shamsaei said. "It's an exciting partnership."
Blue Origin's New Glenn at liftoff during its NG-1 mission in January.
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