NCK MATCA 2 - DP Metal Additive Manufacturing of Permeable Structures for High-End Applications

The project aims to develop, experimentally validate, and optimize a proven technology for manufacturing permeable porous metal structures using metal additive manufacturing technologies. The work is motivated by the need to integrate gas-permeable or fluid-permeable zones directly into tooling and other components, eliminating the need for post-machining operations such as drilling micro-vents or inserting sintered elements. The research will establish a clear and repeatable workflow—from identifying functional requirements, through digital design and process parameter definition, to experimental verification of permeability and mechanical integrity. Particular attention will be paid to the influence of laser power, scanning strategy, and interlayer offset on the formation and interconnection of pores. In parallel, a new approach based on the controlled addition of foaming agents into the metal feedstock will be explored as a means of generating porosity in-situ during the melting process. The proven technology will be verified through systematic testing on printed samples, combining structural analysis (density, pore size, and distribution) with measurements of permeability and mechanical performance. Custom test equipment will be developed to quantify airflow and pressure drop across samples under controlled conditions. The results will serve to define optimized process windows ensuring both adequate permeability and sufficient strength for real-world use. The outcome of the project will be a validated design-to-print proven technology that enables controlled creation of porous metallic regions within solid components. Such regions can serve various functions—venting, cooling, lubrication, or filtration—and can be implemented in tooling, functional, and structural components. The developed approach is expected to reduce mold scrap rates, improve production efficiency, and extend the lifetime of critical parts. The final project deliverable will include guidelines and technical data supporting industrial adoption and commercialization of the developed technology.