UAM

Step 1

Printing

UAM uses thin metal sheets, in the range of 0.1mm to 0.25mm thickness. The first sheet is placed upon the build platform. An ultrasonic welding horn is used to apply ultrasonic vibrations to the sheets. The vibration causes the oxidized layer between the sheets to be removed through friction, allowing the virgin metal surfaces to bond. This is known as "Solid State Bonding". During this process, CNC milling is used to clear out unwanted geometry on each sheet. This technique can create bonds between dissimilar metals without developing a brittle metallurgical bond. Temperature-sensitive components can be embedded within the metal object, part way through the process.

Step 2

Support Removal

Manual Removal Non-applicable in the traditional sense; the UAM process builds parts in solid layers, often incorporating in-situ CNC milling between layers to define geometry. Soluble Support Removal Non-applicable. Manual Cleaning Note: Any excess metal or tab structures may be machined off as part of finishing operations.

Step 3

Surface Finishing

Sanding / Polishing May be required depending on surface finish requirements; most finishing is handled via CNC milling during or after the build. Chemical Smoothing / Coating Anodising, plating, or chemical passivation may be applied to enhance corrosion resistance or aesthetics. Painting / Priming Common for protective or aesthetic purposes; requires standard surface preparation (e.g., degreasing, priming) Gloss / Matte Control Determined by machining parameters or surface treatments post-build.

Step 4

Curing / Heat Treatment

UV / Thermal Curing Non-applicable, as UAM is a solid-state process with no melting or curing involved. Annealing / Stress Relief Rarely needed due to low residual stress; however, heat treatment may still be used to enhance mechanical properties (e.g., precipitation hardening for aluminium alloys.)

Step 5

Assembly and Functional Finishing

Gluing or Bonding Possible, though typically not necessary for fully integrated UAM parts. Drilling / Tapping / CNC Core to the UAM process—machining is integrated throughout the build to achieve tight tolerances and precision features. Inserts / Fasteners Commonly included during post-processing or embedded during printing, including sensors, wiring, and optical fibres.

Step 6

Special Treatments

Infiltration / Sealing Non-applicable; parts are solidly bonded and do not exhibit porosity. Functional Coatings Surface coatings like conductive layers, thermal barriers, or anti-corrosion finishes may be applied depending on the application. Post-print Functionalisation UAM excels at embedding electronics, cooling channels, fibers, and sensors directly into metal components—many parts undergo electrical testing or functional assembly post-print.