The new system, called the iFusion Infinity Series, aims to solve this problem by changing the way metal 3D printing can be used in factories, moving it from an experimental technology to a reliable production process. | Photo Credit: PHOTOS FOR REPRESENTATIVE PURPOSES ONLY
A Bengaluru-based company has developed a metal 3D printing system that can mass-produce high-precision metal parts at nearly half the cost and in a fraction of the time it takes existing machines.
The system can be used not only to design components, but also to actually manufacture them at scale for sectors such as aerospace and defense.
Until now, metal 3D printing in India has largely been limited to testing designs or producing small batches, as the process has been too slow and expensive for large-scale production. The new system, called the iFusion Infinity Series, aims to solve this problem by changing the way metal 3D printing can be used in factories, moving it from an experimental technology to a reliable production process.
Although metal 3D printing existed, its use was limited. Companies relied on it to produce prototypes or a handful of complex parts, after which production would shift back to conventional manufacturing methods such as casting or machining. This was primarily because existing metal printers worked with one or two lasers, making the printing process extremely slow. A single production order can take several weeks to complete, adding to costs.
This system solves this problem by allowing multiple lasers to work on the same metal part at the same time. According to the company, tasks that previously required 400 to 650 hours on conventional dual-laser machines can now be completed in about 140 to 190 hours.
Application
The product supports a wide range of industrial metals, including titanium, nickel-based superalloys, stainless steel, high-strength steel, cobalt, chromium and copper alloys. These materials are commonly used in aerospace components, defense equipment, power systems, automotive parts, and precision tools.
“The biggest shift is predictability. With shorter and more stable build cycles, manufacturers can plan production schedules and calculate costs. This allows metal 3D printing to function as a regular production machine rather than a specialized test tool,” said Sridhar Balaram, Founder and Managing Director, CEO, Intech Additive Solutions.
One of the biggest challenges, Mr. Balaram said, in scaling metal 3D printing is consistency. While existing printers can produce highly accurate parts, maintaining the same quality across tens or hundreds of assemblies is difficult. Over time, changes in heat, laser power, and powder spread can lead to differences between parts.
He added that this product was designed to address this issue. Each of its eight lasers is calibrated to deliver identical energy, while software continuously controls how the lasers overlap and interact. This ensures that a part printed in one corner of the circuit board behaves the same as a part printed elsewhere.
Cost has been another major barrier to large-scale metal 3D printing. The company says its new system can reduce part costs by 35% to 50% compared to existing dual laser machines, depending on geometry and lot size.
This reduction, Mr. Balaram pointed out, does not come from cheaper materials, but from higher throughput and better utilization. “Faster assembly means the same machine can produce many more parts each year, spreading fixed costs such as machine time, labor and equipment overhead over more output. As a result, parts that previously only made economic sense in small numbers can now be produced in much larger volumes,” he added.
Published – 21 Jan 2026 20:07 IST
