Scalmalloy: A High‑Strength Aluminium‑Magnesium‑Scandium Alloy for Aerospace‑Grade Metal 3D Printing

Additive manufacturing continually pushes the boundaries of material science, unlocking new possibilities for parts that were once impossible to produce. A standout breakthrough in this field is Scalmalloy, a high‑strength metal powder alloy engineered specifically for the aerospace sector. Below we explain what Scalmalloy is, why it matters, and how it is redefining 3D‑printed metal components.

Scalmalloy: A Unique Material for Metal 3D Printing

Scalmalloy is an aluminium‑magnesium‑scandium powder alloy crafted for selective laser melting (SLM) and direct metal laser sintering (DMLS)—the leading powder‑bed metal 3D‑printing technologies. Developed by German company APWorks (founded 2013), Scalmalloy debuted to the world in 2016 when APWorks unveiled the Light Rider, a 3D‑printed motorcycle that showcased the alloy’s exceptional light‑weight performance when paired with topology optimisation and generative design.

Compared to conventional aluminium alloys, Scalmalloy combines the lightweight character of AlSi10Mg with a specific strength and ductility that rival titanium (Ti6Al4V). It also delivers superior corrosion resistance and a stable microstructure at high temperatures—qualities that make it ideal for demanding, high‑performance applications. According to APWorks, 3D‑printed Scalmalloy parts can match the performance of traditionally manufactured aluminium components.

Why Scalmalloy is a Perfect Fit for Aerospace

The aerospace industry has long been a pioneer in additive manufacturing, and APWorks designed Scalmalloy with this market in mind. Two key attributes give Scalmalloy a competitive edge:

• Low buy‑to‑fly ratio: This metric—raw material weight versus finished part weight—is crucial for minimizing material waste and cost.
• High strength‑to‑weight ratio: Lighter, stronger parts directly translate to fuel savings and improved aircraft performance. Scalmalloy’s properties make it ideal for use with topology optimisation, enabling designers to remove material without compromising structural integrity.

Broader Applications Beyond Aerospace

Scalmalloy’s versatility extends to automotive, robotics, and other high‑performance industries. A notable example is the front‑end structure prototype for the Volkswagen Caddy, developed through the 3i‑PRINT collaboration between Altair, APWorks, csi entwicklungstechnik, EOS GmbH, GERG, and Heraeus. The project combined generative design, additive manufacturing, and Scalmalloy to create a lightweight, heat‑managed load‑bearing module that traditional manufacturing could not achieve.

Explore the 3i‑PRINT project in detail on the participating partners’ websites.

Advancing Metal 3D Printing

Metal 3D printing is evolving rapidly, with faster, more reliable systems emerging each year. Yet the true value of this technology hinges on the breadth of high‑quality materials available. Innovations like Scalmalloy are pivotal, driving down costs and unlocking new manufacturing possibilities across industries.

For more information, visit APWorks.