Northeast Manufacturing News • Sept 20 • 6K Announces Developments in AM

6K, a developer of microwave plasma technology for the production of advanced materials, announced that its division 6K Additive has commissioned the first two commercial UniMelt systems in its new 40,000 sq. ft. state-of-theart manufacturing plant located in Bugettstown, PA. “The news not only represents a landmark milestone for 6K, but also for global sustainable manufacturing as premium metal additive manufacturing (AM) powders from sustainable sources become a reality,” said a company spokesperson.

6K also announced that it has partnered with Relativity to develop AM rocket parts for space made from sustainable materials.

6K is proceeding through internal product qualification and third-party printing, and will begin customer sampling first for its Onyx In718 material followed shortly by Onyx Ti64. “6K’s first-of-its-kind process has the unique ability to convert certified chemistry machined millings, turnings and other recycled feedstock sources into premium AM-ready metal powders,” said the spokesperson. 6K recently became a member of MESA’s association for sustainable manufacturing and is going through the process of certification as a sustainable manufacturing factory for the new plant.

“The commissioning of the first commercial UniMelt systems is the culmination of terrific work by experts in manufacturing, process and materials at both 6K Additive and our parent company 6K,” said Frank Roberts, President of 6K Additive. “Customers and strategic partners have been eager to sample and use our Onyx powders and we are ready to deliver. Accompanying the new UniMelt systems, the new facility encompasses automated manufacturing equipment and industry leading safety and health systems that confirm our organization is hitting our production goals while ensuring the utmost in safety for our employees.”

“The UniMelt system is the world’s only microwave production-scale plasma, with a highly uniform and precise plasma zone with zero contamination, and capable of high throughput production of advanced materials including Onyx In718 and Onyx Ti64 AM powders,” said the spokesperson. 6K’s UniMelt technology can also spheroidize ferrous alloys like SS17-4PH, SS316, other nickel superalloys including Inconel 625, HX, cobalt-base alloys like CoCr, refractory metals like Mo, W, Re, reactive alloys such as Ti-6-4, TiAl, Al alloys as well as high-temperature ceramics such as MY and YSZ.

The new facility is near 100% completion and has significant expansion capabilities on the company’s 45-acre site. The facility has additional manufacturing bays and the company plans to commission additional UniMelt systems throughout 2021 to meet the demand for its premium AM powders.

6K has announced a strategic partnership with Relativity Space to prove true sustainability in AM production. “Relativity Space is the world’s first autonomous rocket factory and launch services leader for satellites,” said a spokesperson. The partnership is intended to create a closed loop supply chain where certified scrap materials produced at Relativity are turned into powder by 6K, which can then be reprinted by Relativity. The two companies will also explore new materials created specifically for rocket manufacturing and space travel.

“Relativity is completely reimagining the aerospace supply chain by creating an autonomous robotic factory that can additively manufacture a rocket in 60 days. This partnering with 6K will add another important element to our very unique approach: the ability to reuse materials,” said Tim Ellis, CEO of Relativity. “We are looking forward to working with 6K to add this sustainability to our supply chain, while ensuring closed loop traceability all the way through.”

Dr. Aaron Bent, CEO of 6K, added, “Relativity is pushing the boundaries of AM by 3D printing a complete rocket, and we see this partnership as a natural extension of their forward-thinking practice. Our ability to turn their used powder and parts into premium powder through the UniMelt process provides them with a sustainable source for AM powder. We are proud to be partnering with Relativity to explore ways to increase sustainability, recycling and environmentally responsible manufacturing processes, which the entire AM industry is uniquely posed to be able to integrate into standard practices.”

As part of the collaboration, the two companies have signed an agreement detailing a three-phase approach from a proof of concept all the way through a Relativity printed part. The project will prove out the process of taking scrap material produced directly at Relativity, utilizing 6K’s UniMelt proprietary process to deliver premium certified powder, to a final printed part suitable for Relativity’s production. “Working with the 6K process ensures Relativity will have complete line of sight and control of its supply chain while ensuring certified AM chemistry for production parts that are suitable for the rigors of a rocket launch and space travel,” said the spokesperson.

“Lastly, both organizations see sustainability as a key requirement for production. Creating high-quality additive powders from something that was previously viewed as machine scrap showcases that the process significantly contributes to a circular economy and positions Relativity and 6K as pioneers of sustainability in AM production,” concluded the spokesperson.

For more information contact: 6K 25 Commerce Way North Andover, MA 01845 978-258-1645 www.6Kinc.com