From research to application: enabling advanced materials in 3D printing

"Normal materials lose their strength when exposed to high temperatures, but these specific alloys retain their strength, which is crucial for certain applications like aeroplane engines and turbines for power generation," says Shaafi Shaikh.

However, adapting these superalloys for 3D printing is far from straightforward, due to risks like crack formation, potential loss of high-temperature durability, and high production costs.

"Through the research, we’ve learned that in order to make these materials suitable for 3D printing, we need to study their compositions carefully and adjust them to achieve the right melting and freezing behavior. We also need to redesign heat treatments to ensure the necessary strength and endurance".

The research focuses on advancing 3D printing technology for superalloys, enabling the production of more complex, efficient, and resilient parts.

“With 3D printing, we can design and manufacture more efficient components while reducing environmental impact. At the same time, we simplify complex supply chains. For example, a turbine part that currently takes years to deliver could be produced locally and far more quickly”.

Staying close to the application

As an industrial PhD student, Shaafi Shaikh emphasizes the value of being close to the application of technology. In industries with rapidly evolving technologies like 3D printing, staying connected to advancements in the industry is important.

"Being an industrial PhD has given me unique insights into the practical applications of my research. I think being close to industry is essential when trying to solve real-world problems,” he says.

Strong collaboration between EOS and CAM²

Shaafi Shaikh carries out his industrial PhD work at EOS, a pioneer in 3D printing technology and one of the first companies to adopt metal additive manufacturing. Olli Nyrhilä, Chief Engineer of Metal Materials & Processes at EOS, sees the partnership with CAM² as a natural fit.

"Chalmers is the home base of Swedish metal powder research, so it was a very good match from the beginning. The CAM² centre involves industrial partners across the entire value chain, making it an ideal environment for collaboration between academia and industry,” says Olli Nyrhilä.

Commercial application on the horizon

The results of the research are already starting to make an impact. Several of the nickel-base superalloys being studied are progressing towards commercial application, drawing attention from end-user industries.

“Having Shaafi Shaikh as an industrial PhD has been a great advantage. One of the key contributions he brings is the ability to dive deep into the metallurgy of these alloys, to identify the underlying problems and gradually develop effective solutions,” says Olli Nyrhilä.

For Shaafi Shaikh, working at the intersection of academia and industry has been key.

“In industry, we know how to get things done. But understanding why certain solutions work unlocks a whole new level of problem-solving. That’s where the collaboration between academia and industry really excels. We solve practical problems while deepening our knowledge,” he says.

Looking ahead

After defending his PhD, Shaafi Shaikh looks forward to expanding the practical applications of his research and continuing to bridge academia and industry.

“The PhD is a great foundation for research. It’s given me the tools to ramp up my efforts and apply the problem-solving skills I’ve developed. I feel there’s still a lot I can contribute, and whether that’s in academia or industry doesn’t really matter, since we work so closely together,” he says.

Shaafi Shaikh defends his PhD thesis, Additive manufacturing of Ni-base superalloys: Processing, heat treatment, productivity, and properties, on 9 May 2025.