Elmet Technologies has been granted U.S. Patent No. 12,571,080 for the fabrication of metallic parts using additive manufacturing. The patent covers a method for producing three-dimensional objects from a dry powder bed of substantially spherical composite particles, specifically tungsten heavy alloys containing nickel, iron, copper, cobalt, or manganese. Developed by a team led by Vice President of Research and Development Michael T. Stawovy, the process utilizes spray drying and plasma densification to achieve high flowability and minimal shrinkage during sintering. The technology is compatible with both binder jetting and wire-based directed energy deposition, with finished parts meeting ASTM B777 Class 1 specifications for density and tensile strength.

This patent strengthens Elmet Technologies' position in the refractory metal market, addressing the historical difficulty of processing tungsten into complex geometries via additive manufacturing. By controlling particle architecture and impurity levels, the company competes with traditional powder metallurgy and specialized metal AM providers serving the aerospace and defense sectors. The ability to produce flowable, high-purity tungsten powders is a critical bottleneck in the supply chain for extreme-environment components. This development allows Elmet to offer a domestic, vertically integrated solution for high-performance refractory parts that previously required complex, multi-stage manufacturing routes.

This patent provides Elmet Technologies with a clear defensive moat for its proprietary powder processing techniques. Users in the defense and aerospace sectors should evaluate the mechanical performance of these tungsten alloys against existing wrought or sintered benchmarks to determine suitability for specific high-stress applications. The company must now focus on scaling the production of these composite powders to meet industrial demand for larger-scale additive manufacturing deployments.