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Photo of a 3D printer - printing a metal part

Optimizing the Entire Product Lifecycle with Additive Manufacturing

End-to-end applications

Printed on the ElemX

From prototyping to production and beyond. The ElemX liquid metal 3D printer is capable of producing faster and more cost-effective parts than ever before. Truly embracing the future of distributed and on-demand manufacturing. The 3D printed parts below are made from aluminum alloy wire feedstock and designed by our partners and users.

Gallery of 3D printed parts

New Product Development

Photo of a Production Motor Mount Plate

Production Motor Mount Plate​

​​​The motor mount in the prior architecture did not meet the requirements for a future planned design iteration. This new design replaced the original sheet metal mounting plate and enabled the engineering team to offset the motor a few millimeters, without having to create new tie bars or subframe components.​

Part

Production Motor Mount Plate

XYZ Dimensions (mm)​

150 x 75.85 x 9.53​

Print Time​

2 Hours​

Mass​

165 Grams​

Material​

AL 4008​

 



Photo of a Fluid Distribution Nozzle

Fluid Distribution Nozzle

​​​The fluid distribution nozzle is used to separate fluid flow from a singular source to nine different flow paths. The nozzle is non-clogging, operates at very low spray pressures and evenly distributes flow over a wide area. Printed in AL 4008 enables this particular device to operate in harsher environments using chemicals, oils, and gasoline. Depending on the specific application, AL 4008 has excellent corrosion resistance properties and is ideal for automotive, aerospace and energy industries. 

Part

Fluid Nozzle

XYZ Dimensions (mm)​

91 x 91 x 120​

Print Time​

6 Hours, 38 Minutes​

Mass​

234 Grams​

Material​

AL 4008​

 



Photo of a heat sink

Heat Sink

​​​The heat sink is used to house a chemical reactor cooling unit and is typically exposed to extreme temperatures. The fins are used to dissipate heat and drive it away from the reactor, enabling it to reliably operate. This type of heat sink design is commonly used in challenging environments associated with automative, aerospace, or heavy machinery applications that deal with corrosive or hazardous materials.

Part

Heat Sink

XYZ Dimensions (mm)​

136.63 x 136.63 x 50​

Print Time​

6 Hours, 22 Minutes​

Mass​

434 Grams​

Material​

AL 4008​

 



A Xerox ElemX 3D print of a pump housing

Pump Housing

​​​Fluid pumps are widely used in industrial application for fluid transfer and low-pressure agricultural spraying applications. The pump assembly must withstand constant operating pressure while providing long lasting durability. Printing in 4008 Al (A356) enables engineers to reduce weight and retain strength while dramatically impacting long lead times. 

Part

Pump Housing

XYZ Dimensions (mm)​

115 x 80 x 70​

Print Time​

5 Hours, 25 Minutes​

Mass​

490 Grams​

Material​

AL 4008



A Xerox ElemX 3D print used in the auto industry

Auto Bracket

Designed and utilized by one of the top luxury automobile manufacturers in the world, the automotive bracket operates as a fixation of hot aluminum parts, therefore an inner cooling channel is necessary. Combining the benefits associated with DfAM and the strong mechanical and cost benefits of aluminum enable this OEM to manufacture on-demand with high performing parts that won’t break the budget.

Part

Auto Bracket

XYZ Dimensions (mm)​

115 x 37 x 28​

Print Time​

2 Hours, 15 Minutes​

Mass​

490 Grams​

Material​

AL 4008

Low Volume Production

Photo of a Heat Transfer Cylinder Head

Heat Transfer Cylinder Head

The ability to transfer heat with additive manufacturing provides unique benefits due to advanced design and material possibilities. The cylinder head draws heat away using the thin fins, enabling engineers to optimize new designs for high performance applications. Al 4008 is an excellent alloy for thermal conductivity.

Part

Heat Transfer Cylinder Head

XYZ Dimensions (mm)​

139.98 x 140 x 60.87​

Print Time​

8 Hours, 16 Minutes​

Mass​

563 Grams​

Material​

AL 4008​



Photo of a Multi Axis Loaded Bracket

Multi Axis Loaded Bracket​

The centerpiece of a complex assembly, the loaded bracket must simultaneously withstand multi-axis loads and meet tolerance expectations to function with other components. The ElemX metal 3D printer successfully builds high resolution parts with exceptional density characteristics (>99%).

Part

Multi Axis Loaded Bracket

XYZ Dimensions (mm)​

62 x 62 x 27​

Print Time​

1 Hour, 16 Minutes​

Mass​

86.58 Grams​

Material​

AL 4008​



A Xerox ElemX 3D print of an exhaust nozzle

Exhaust Nozzle​

Tear drop internal channels are used to cool the exhaust nozzle for high temperature applications. The ElemX is capable of printing unsupported angles of 45°or higher, making it possible to design better performing parts that would be challenging compared to conventional methods.

Part

Exhaust Nozzle

XYZ Dimensions (mm)​

72 x 72 x 96​

Print Time​

3 Hour, 10 Minutes​

Mass​

252 Grams​

Material​

AL 4008



A Xerox ElemX 3D print of a light fixture

Light Fixture

Identified as one of the top five most commonly replaced items aboard a US Navy ship, the light fixture is imperative to keep the lights on. Printing on-demand with ElemX eliminates the need to store simple parts aboard the ship, providing more space for food, ammunition, and other important items require to complete the mission.

Part

Light Fixture

XYZ Dimensions (mm)​

165 x 165 x 400​

Print Time​

3 Hour, 5 Minutes​

Mass​

309 Grams​

Material​

AL 4008

Manufacturing Aids

Photo of a Mounting Guide

Mounting Guide

This part has been designed for your review, use, destructive testing and analysis. Included is a section for you to machine, review potential finishing options, or create mechanical test specimens for further characterization. The intent is to allow for a deeper assessment of ElemX’s performance.​

Part

Mounting Guide

XYZ Dimensions (mm)​

130 x 110 x 13​

Print Time​

3 Hours​

Mass​

368 Grams​

Material​

AL 4008​



Photo of a Graphite Heater Inspection Jig

Graphite Heater Inspection Jig

This 10-sided jig was designed to inspect the ElemX print head graphite heater slots produced on the Xerox manufacturing line. For precise inspection, the jig orients each slot directly perpendicular with the microscope; therefore requiring accurate dimension tolerances. This particular jig was designed and printed several times in a 24-hour period.

Part

Graphite Heater Inspection Jig

XYZ Dimensions (mm)​

67.9 x 50 x 63​

Print Time​

4 Hours​

Mass​

260 Grams​

Material​

AL 4008​

Spares & Repairs

Photo of Actuator Caps

Interlock Actuator Cap

An important switch used by our Technical Services community needed to be redesigned to be RoHS 3 compliant. In doing so, the guides were removed, resulting in worn interlocked actuators that periodically slip off the switch plunger. The technical service representatives reported difficulty using this new switch design in their troubleshooting tasks, stemming directly from the interlock changes. The cap was designed to fit on top of the actuator, engaging the switch every time.

Part

Interlock Actuator Cap

XYZ Dimensions (mm)​

34.5 x 9.9 x 20​

Print Time​

22 Minutes​

Mass​

22 Grams​

Material​

AL 4008​



A Xerox ElemX 3D print of an actuator body

Pneumatic Actuator Body

Automation components are standardized and relatively convenient for a multitude of applications. However, redesigns are necessary for space and performance purposes. The custom device is a prime example of when metal AM can impact product development and provide benefits later in the product lifecycle by retrofitting existing equipment to optimize performance or bypass obsolescence issues. 

Part

Pneumatic Actuator Body

XYZ Dimensions (mm)​

45 x 58 x 86​

Print Time​

3 Hours, 15 Minutes​

Mass​

232 Grams​

Material​

AL 4008



A Xerox ElemX 3D print of a valve for a ship

US Navy Ship Valve

Identified as one of the most commonly replaced items aboard a US Naval ship, the valve must perform in the most rugged conditions possible – humidity, vibration, salt air, etc. Instead of utilizing valuable storage space for simple and common replacement parts, Sailors can print parts on-demand when necessary. This enables the military to use storage space for other mission critical items. 

Part

US Navy Ship Valve

XYZ Dimensions (mm)​

152 x 152 x 25​

Print Time​

3 Hours, 30 Minutes​

Mass​

355 Grams​

Material​

AL 4008