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Additive Manufacturing

EOS Aluminium Al5X1 – a new aluminium alloy for 3D printing

EOS, a supplier of manufacturing solutions for industrial 3D printing, has announced the addition of a new aluminium alloy, EOS Aluminium Al5X1. 

EOS Al5X1 anodized example parts

EOS Aluminium Al5X1 is specifically engineered for additive manufacturing, but at a more competitive cost than other aluminium alloys with similar strength and elongation properties. It delivers excellent performance and material properties with a combination of high strength (around 410 MPa UTS) and elongation (14 %).  

Single-step heat treatment without water quench 

Requiring only a single-step heat treatment with no HIP (Hot Isostatic Pressing), organizations manufacture parts faster and at a lower total cost. 3D printed applications using EOS Aluminium Al5X1 can also be electropolished and anodized for both cosmetic (coloured) and corrosion-resistant protective properties. There are no limits to potential colour choices, which could be important to consumer-facing products. 

EOS Aluminium Al5X1 was tested by multiple organizations including world-leading semiconductor, aerospace and defence companies. Early adopters have noted that the material’s exceptional performance combined with the competitive cost-per-part (CPP) has created a strong business case for production implementation. 

Ideal for aviation, consumer electronics and transport industries 

”Since early 2023, we have been working to develop Al5X1 performance data and material allowables on behalf of our prime customers,” said Brian Neff, founder and CEO of Sintavia, a designer and additive manufacturer of mechanical systems for the aerospace and defence industry. “Preliminary results are very promising, and we look forward to introducing Al5X1 across our thermodynamic product lines. Developing a higher performing aluminium alloy is of critical importance not only to us, but also to the industry as a whole.”

“A combination of high strength and high elongation for an aluminium alloy is critical for manufacturers in industries like aerospace, but equally crucial is delivering the property combination at a reasonable cost,” said Ankit Saharan, senior manager of metals technology at EOS. Also interesting is that since the material can be anodized, this makes it very attractive to OEMs in areas like consumer electronics who are seeking to produce different coloured products to suite customers preferences, with the added bonus of corrosion resistance.” 

EOS Aluminium Al5X1for the EOS M 290 will be commercially available in November 2023, followed by commercial availability for the EOS M 400-4 in 2024.

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