Rovalma SA, Barcelona, Spain

Isaac Valls

Biography

Coming soon

Conferences

Room

Date

Hour

Subject

Room 6

25-03-2026

11:15 am – 11:35 am

81 High-Speed Large-Layer Additive Manufacturing: Bridging the gap between design freedom and serial production

Conferences Details

81 High-Speed Large-Layer Additive Manufacturing: Bridging the gap between design freedom and serial production

We present a disruptive, metal additive manufacturing technology that introduces a fundamental progress by using hologram based volumetric fabrication with layer thicknesses of 25 mm, achieving build rates up to 1000x faster than conventional thin layer by layer processes. The method enables the production of sound and homogeneous structures for any kind of metal alloys, including recycled aluminium feedstocks and carbon-based high-performance tool steels. Demonstrator cases highlight its potentials for aluminium and steel components. For aluminium structural parts printed with this new technology, tooling and welding steps are eliminated, achieving up to 90% reduction in lead times while cutting embodied carbon emissions. In another case, a hot-stamping die designed with conformal cooling channels demonstrated >70% raw material savings, improved thermal conductivity, cooling rate and superior hardness compared to forged tooling. Beyond these cases, the technology offers exceptional scalability for industrial production: from large parts to high volume runs, it combines metal alloy versatility with throughput and cost levels that rival conventional processes, while maintaining sustainability through circular feedstocks and drastically lower energy input. This disruptive additive manufacturing method is not a niche prototyping tool, but it is a viable, competitive manufacturing platform ready to serve mainstream mobility and energy sectors at industrial scale.

Keywords: Metal Additive Manufacturing (MAM); High strength aluminium, Volumetric metal 3D printing

An event by Metal AMS – Metal Additive Manufacturing Synergy