WRITER: Allison Brady, engr_media@nmsu.edu
Researchers at New Mexico State University have been working on a new method of metal 3D printing that could allow scrap metal to be made into high quality materials.
Chaitanya Mahajan, NMSU industrial engineering assistant professor, is a co-principal investigator for a nearly $3 million grant awarded to Rochester Institute of Technology by the National Science Foundation.
One of the biggest barriers in modern 3D manufacturing is meeting the demand for high-quality metal parts at scale without incurring high costs or generating waste. Traditional metal 3D printing is often slow and expensive, limiting its practical use.
Molten metal droplet jetting uses millions of tiny molten metal droplets that build on each other as they fuse during cooling. While there are current 3D printing models that use this method, the team’s new approach could directly compete with modern industry practice by reducing material waste and enabling the use of recycled metals.
Most current 3D printers melt their material during printing. Mahajan said this process limits the materials that can be used with most printers, requiring users to purchase specialized materials.
“Many traditional metal 3D printers require highly specialized, expensive and potentially hazardous spherical metal powders,” Mahajan said. “These powders have a limited shelf life, absorb moisture, and present severe explosion and inhalation risks, making them incredibly difficult to transport and store in harsh environments.”
This version of molten metal droplet jetting will allow for materials to be melted before printing. This separation of melting and deposition enables dramatically faster production and opens the door to using a wide range of materials, including low-cost and recycled feedstocks, as machining scrap.
“For me, transforming aluminum scrap into high-precision parts redefines the limits of additive manufacturing,” Mahajan said. “This project demonstrates that the future of mass production lies in bridging the gap between circular sustainability and next-generation engineering.”
Another hurdle the team is trying to tackle is the limits most molten metal droplet printers have due to the use of a single printing nozzle. Using a single nozzle tends to be slow and frequently causes clogging, halting the production process.
By using multiple nozzles and advanced modeling techniques, the team can increase production rates while maintaining quality. At the same time, the process enables the direct reuse of scrap metal, turning what would normally be waste into valuable, high-performance components.
Mahajan said having the ability to convert scrap metal into usable parts has important implications for both commercial and defense supply chains. In environments where materials are limited or difficult to source, this technology could provide a reliable and cost-effective solution for producing critical components on demand.
“The ability to create cost-effective 3D printed components will be essential when creating multi-material smart structures,” Mahajan said. “Allowing manufacturers to print embedded wiring and data components into structures, eliminating the weight and clutter of traditional external wiring harnesses.”
For NMSU, the award is helping increase the quality and reach of additive manufacturing research.
“Dr. Mahajan’s work represents the forward-thinking, impactful research we strive to advance in industrial engineering,” said Hansuk Sohn, NMSU department head of industrial engineering and Nakayama endowed professor. “This project not only pushes the boundaries of additive manufacturing but also addresses critical challenges in sustainability and supply chain resilience. We are proud to see NMSU playing a key role in shaping the future of manufacturing through innovations like these.”
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CUTLINE: Chaitanya Mahajan, right, industrial engineering assistant professor at New Mexico State University, is part of a team that received a nearly $3 million grant for research that allows scrap metal to be made into high-quality materials. (NMSU =photo by Vladimir Avina)
Description: A professor and student hold scrap metal parts in a lab where they melt and reuse the metal.
CUTLINE: Chaitanya Mahajan, an industrial engineering assistant professor at New Mexico State University, and a student hold scrap metal that can be used in a molten-metal droplet-jetting 3D printer. Mahajan is part of a team that received a nearly $3 million grant from the National Science Foundation to make scrap metal into high-quality materials. (NMSU Photo by Vladimir Avina)
Description: Two hands hold scrap metal parts in a lab where they melt and reuse scrap metal.
