3D Printing Industrial Carbide: Harder, Faster, Greener

The tools that build our world are often invisible to us, yet they are the silent backbone of modern civilization. From the high-precision drills that carve out the infrastructure of our cities to the cutting edges that shape the components of our vehicles, the secret to their durability lies in a material known as tungsten carbide-cobalt. This cemented carbide is one of the hardest substances known to man, sitting just below diamond on the scale of toughness. However, the very strength that makes it indispensable also makes it notoriously difficult and wasteful to manufacture.

A study¹ from Hiroshima University, in collaboration with Mitsubishi Materials Hardmetal Corporation, has recently unveiled a new path forward. By combining additive manufacturing—popularly known as 3D printing—with a specialized hot-wire laser method, researchers have found a way to create industrial-grade components that are just as tough as those made with traditional methods, but with significantly less waste. This development is not just a win for the factory floor; it is a glimpse into a future where high-performance materials are accessible, sustainable, and customizable.

Why Tungsten Carbide Is Difficult to 3D Print

Traditionally, creating parts from tungsten carbide-cobalt is a grueling and expensive process. It relies on powder metallurgy, where metal powders are pressed together under immense pressure and then heated in a furnace until they bond, a process called sintering. While this produces incredibly hard tools, it is a rigid process. Creating complex or large shapes is difficult, and much of the expensive raw material—tungsten and cobalt—is wasted in the process.

The high cost of these raw materials is a major hurdle. Tungsten is rare and expensive, and cobalt is a critical mineral with a volatile supply chain. In an era where sustainability and resource efficiency are paramount, the old ways of subtractive manufacturing—where you start with a block of material and cut away what you do not need—are increasingly seen as outdated.

How the Hot-Wire Laser Method Enables 3D Printing of Tungsten Carbide

The innovation from the Hiroshima University team lies in a subtle but profound shift in how we think about 3D printing metal. Most metal 3D printers work by fully melting metal powder or wire with a high-energy laser. However, when you try to do this with tungsten carbide, the extreme heat causes the material to decompose into W2C and graphite, leading to tiny holes, cracks, and a loss of the very hardness that makes it valuable.

Instead of fighting the material’s nature, the researchers used a hot-wire laser method. In this setup, a cemented carbide rod is pre-heated by an electric current to near its melting point before it even reaches the laser. The laser then provides just enough additional heat to soften the material, allowing it to be deposited layer by layer.

By softening the material rather than fully melting it, the team managed to preserve the delicate microstructure of the tungsten carbide. They discovered that by keeping the temperature above the melting point of the cobalt binder but below the threshold where the tungsten carbide begins to break down, they could produce a solid, defect-free object with a hardness of over 1400 HV—matching the quality of traditional industrial tools.

Solving Additive Manufacturing Defects in WC-Co Carbide

One of the cleverest aspects of the study was how the team handled the interaction between the ultra-hard carbide and the base material it was being printed on. When they tried to print directly onto a standard iron base, the iron would often invade the carbide, diluting its strength.

The solution was the introduction of a middle layer made of a nickel-based alloy. This layer acts as a buffer, preventing the base material from contaminating the carbide and ensuring the final product remains pure and strong. This multi-material approach is a key trend in 3D printing, allowing engineers to put the expensive, high-performance material only where it is truly needed—like the cutting edge of a tool—while using cheaper materials for the rest of the body.

Why 3D Printing Tungsten Carbide Could Transform Manufacturing

The potential of this technology extends far beyond the laboratory. As these methods are refined to handle more complex shapes and eliminate the remaining issues with cracking, the implications for our world are vast.

• On-Demand Industrial Resilience: Imagine a world where a remote mining site or a construction project does not have to wait weeks for a replacement part to be shipped from a central warehouse. With advanced 3D printing, critical, ultra-hard components can be manufactured on-site, exactly when they are needed.
• Sustainability and Resource Security: By only using the exact amount of tungsten and cobalt required for a specific part, we can dramatically reduce our reliance on mining and minimize industrial waste. This is a crucial step toward a circular economy where materials are used with maximum efficiency.
• Next-Generation Design: Traditional manufacturing limits what we can build. 3D printing removes those shackles, allowing for the creation of tools with internal cooling channels, complex geometries, and optimized weights that were previously impossible to manufacture. This leads to more efficient machines, lighter vehicles, and more durable infrastructure.

Investing in Industrial 3D Printing and Advanced Materials

As the industrial sector moves toward smarter and more efficient production, the companies providing the hardware and materials for this transition are positioned for significant growth. For investors looking to capitalize on the advancements in metal 3D printing and high-performance materials, one company stands out as a primary player in the space.

Spotlight: Nano Dimension (NNDM -5.94%)

While many 3D printing companies focus on consumer plastics or simple metals, Nano Dimension has positioned itself as a leader in the high-performance, industrial side of the market. The company recently underwent a major strategic shift by acquiring Desktop Metal, a pioneer in metal binder jetting and advanced material deposition.

This acquisition has transformed Nano Dimension into a comprehensive provider for industrial additive manufacturing. Desktop Metal’s technology is already being used by researchers and manufacturers to explore the very types of cemented carbide applications highlighted in the Hiroshima University study. By merging their expertise in electronics 3D printing with Desktop Metal’s robust metal platforms, Nano Dimension is building a full-stack solution that covers everything from rapid prototyping to mass production.

Financially, the company has shown impressive growth, recently reporting an 81 percent year-over-year increase in revenue. While the industry is still in a high-growth, high-investment phase, Nano Dimension’s massive portfolio of patents and its focus on critical sectors like aerospace, automotive, and defense make it a compelling choice for those looking to invest in the future of manufacturing. As technologies like the soft-melting hot-wire method move from the lab to the production line, companies with the infrastructure to support these advanced processes will be the ones to watch.

Latest Nano Dimension (NNDM) Stock News and Developments

References:

^{1. Marumoto, K., Abe, T., Nagamori, K., Ichikawa, H., Nishiyama, A., & Yamamoto, M. (2026). Effect of the hot-wire laser irradiation method and a Ni-based alloy middle layer on mechanical properties and microstructure in additive manufacturing of WC-Co cemented carbide. International Journal of Refractory Metals and Hard Materials, 136, Article 107624. https://doi.org/10.1016/j.ijrmhm.2025.107624}