Expert Interview: Armin Wiedenegger of voestalpine High Performance Metals on Metal 3D Printing Innovation

Metal 3D printing is increasingly transforming high‑value, low‑volume manufacturing across many sectors. Its continued evolution hinges on the development of new, high‑performance materials.

voestalpine, one of Europe’s largest steel‑technology leaders, has become a key player in advancing these materials. After establishing its expertise in additive manufacturing (AM) at its High Performance Metals division, the company opened its first Additive Manufacturing Centre in Düsseldorf in 2016 and has since expanded to sites in Taiwan, North America and Singapore.

In this expert interview, AMFG speaks with Armin Wiedenegger, Strategy & Business Development for Additive Manufacturing at voestalpine High Performance Metals GmbH, to explore the company’s metal AM powders, cutting‑edge applications, and success stories.

About voestalpine

voestalpine is a global technology and capital goods group that combines deep material science with advanced processing expertise. It partners with the automotive, consumer goods, aerospace and oil & gas sectors worldwide, delivering steel‑based products and system solutions.

The Additive Manufacturing activities fall under the High Performance Metals Division, a global leader in tool steel, high‑speed steel, valve steel, and specialty alloys, as well as in powder materials, nickel‑based alloys and titanium components fabricated through AM technologies.

Material Development Challenges and Timeline

Developing powders for metal AM is a meticulous process. Creating a brand‑new alloy can take 1–3 years, while optimizing existing alloys typically requires up to one year of research, testing and validation.

High‑quality metal powders—characterized by closely packed, spherical particles of uniform size—are critical for consistent parts. At voestalpine, these powders are produced via a precise gas atomisation process that converts an existing alloy into a high‑performance powder in just a couple of weeks.

Global 3D Printing Centres and Technologies

The High Performance Metals Division operates several AM centres worldwide, utilizing two primary technologies:

• Powder Bed Fusion (PBF) – Ideal for intricate designs; offers high resolution but is slower and more expensive.
• Direct Metal Deposition (DMD) – Uses powder and wire feedstock; more cost‑effective but offers limited design flexibility.

Target Industries

The company focuses on the toolmaking and oil & gas markets, where the benefits of metal 3D printing are most pronounced.

Success Stories

One standout achievement is the LightHinge+—a lightweight engine hood hinge developed for automotive use in partnership with Edag and Simufact. Traditional manufacturing of this component is expensive, with high tooling costs and a typical weight of 1.5 kg per hinge. For a vehicle requiring around 40 hinges, this adds significant weight.

Using topology optimisation and advanced simulation, the team produced the hinge entirely via PBF, reducing support material from over 50% to under 18% of the part’s weight. This optimisation also cut post‑processing time. The final result achieved a 50% weight reduction compared to conventional sheet‑metal fabrication.

Industry Outlook

AM is transitioning from single‑piece prototypes to serial production, signalling growing confidence in the technology as a viable manufacturing solution.

Remaining Challenges

To accelerate adoption, the industry must address:

• Improving production speeds.
• Reducing equipment costs to broaden market access.
• Consolidating the AM value chain—including design, manufacturing, and post‑processing software—to streamline operations.

To learn more about voestalpine’s High Performance Metals Division, visit: voestalpine High Performance Metals