Additive technologies are permeating game-changing innovations in manufacturing. Presently, the status quo in metal additive manufacturing is centred on the fabrication of small parts with optimization performed for weight savings and performance using mainly laser powder-bed 3D printing technology. For the production of large parts, the manufacturing approach entails migrating to higher deposition rate 3D printing. In this regard, wire-fed electron beam additive manufacturing (EBAM) is gaining momentum as an enabling technology for the fabrication of near net shape metallic components through a rapid layer by layer deposition process. Specific advantages of the EBAM process are the relatively large build envelope – that becomes infinite for in-space production – combined with the near 100% material efficiency of the wire-feed into the melt pool and high bulk material deposition rates. This lecture explores some of the additive research at the National Research Council Canada to address the different underlying challenges presently facing the global scientific and research communities for introducing, producing and qualifying materials and structures fabricated through an additive approach.

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