What MOLDJET AM Technology Brings to Mechanical Engineers: Manufacturing Superpowers

3D metal printing has transitioned from a niche technology into an integral tool for modern mechanical engineering design. As engineering requirements push toward higher efficiency, lower weight, and more complex part geometries, additive manufacturing (AM) technologies such as MOLDJET provide engineers with new degrees of freedom. Unlike conventional subtractive methods, MOLDJET enables the design of components based on functional requirements rather than manufacturing limitations.The following sections outline several fundamental mechanical engineering concepts and explain how they are enhanced by this process.

Heat Transfer – Surface Area Optimization In thermal design, the heat transfer capability of a system is mainly related to its available surface area. Traditional manufacturing methods impose severe constraints on internal path complexity within a given volume a critical parameter for heat exchange. MOLDJET enables the fabrication of highly detailed surface features, tailored channel paths, and complex micro-geometries to increase the heat transfer coefficient. The result is compact heat exchangers that can achieve significantly higher coefficients of performance (COPs) within a given volume.

Solid Mechanics – Lattice Structures A crucial part of mechanical design is achieving the lowest possible mass without compromising the necessary stress-bearing capabilities. This can be achieved by implementing lattice structures within the designed part. MOLDJET supports the direct printing of complex lattice and organic structures in metals and ceramics with high geometric fidelity. This capability allows engineers to optimize their designed components with a high level of confidence, which is particularly relevant in aerospace and automotive applications. Geometric Complexity and Design Freedom One of the primary advantages of additive manufacturing is the ability to generate geometrical features that are not achievable with traditional manufacturing technologies, such as complex undercuts. MOLDJET enables the direct production of components with closed internal channels, intricate internal manifolds, and integrated cavities. For mechanical engineers, this provides new pathways to design according to function—for example, embedding internal cooling passages within turbine components or integrating vacuum channels within ceramic parts.

Fluid Mechanics – Flow Regime Control and Topology Optimization Many engineering applications require precise control of fluid dynamics. Surface roughness and controlled turbulence can be harnessed to enhance mixing and increase heat transfer rates. With MOLDJET, internal and external surfaces can be manufactured with engineered texturing to induce vortices, promote turbulence, or guide laminar flow depending on design objectives. This level of geometric precision is critical in nozzles, fuel injectors, and microreactors. Uniform Mechanical Properties A common limitation of many additive manufacturing methods is anisotropic properties between build directions. MOLDJET produces dense metallic or ceramic components with isotropic mechanical characteristics in all axes, enabling engineers to rely on predictable performance under multiaxial loads—a fundamental requirement in rotating machinery, load-bearing automotive parts, and high-reliability aerospace systems. Reduced Post-Processing of Hard Materials Materials such as tool steels, Inconel alloys, and engineering ceramics are both expensive and difficult to machine using conventional processes due to tool wear, machining time, and complexity. MOLDJET mitigates these issues by producing near-net-shape components with an accuracy of approximately ±0.2 mm. For many applications, this reduction in secondary machining drastically decreases manufacturing costs and increases the feasibility of using advanced high-temperature or corrosion-resistant materials. Functional Integration – Assemblies and Multi-Body Design Conventional mechanical assemblies often rely on a large number of discrete components connected by fasteners or welds, introducing fatigue-prone interfaces. MOLDJET supports the manufacturing of entire assemblies as a single monolithic component, incorporating the functionality of multiple parts. This reduces total part count, simplifies maintenance, and increases structural reliability by eliminating weak interfaces.

Rapid Design Iteration and Parallel Prototyping In product development, iterative testing is a standard engineering approach. MOLDJET allows engineers to manufacture multiple design variants of the same part within a single printing cycle, providing a platform for rapid evaluation of performance differences. This capability accelerates development timelines and enhances the optimization process by enabling data-driven design adjustments at early stages. Conclusion

For mechanical engineers, MOLDJET represents a shift from design-for-manufacturing toward design-for-performance, where thermal, structural, and fluid-dynamic objectives dictate component design rather than process constraints. AMT METAL’s expertise in this technology provides engineers with reliable, high-precision additive manufacturing solutions for both metals and ceramics, supporting applications that demand mechanical robustness, geometric complexity, and material efficiency.