MetalMaker

About MetalMaker

MetalMaker operates in the advanced manufacturing sector, providing a distinct solution for producing custom metal parts that bridges the gap between traditional casting and modern additive manufacturing. The company, backed by venture capital from Techstars and Stanley Black & Decker, was founded by Eric Sammut. The firm's history includes its selection for the Techstars and Stanley Black & Decker additive manufacturing accelerator, the establishment of an R&D facility in Europe in 2020, and the development of its first complete system prototype in 2022.

The core of MetalMaker's business is its proprietary MetalMaker System, which employs a process called Additive Pattern Metal Casting (APMC). This method integrates Fused Deposition Modeling (FDM) 3D printing of polymer patterns with industrial investment casting. This hybrid approach allows for the design freedom and rapid iteration of additive manufacturing while delivering the isotropic mechanical properties and precision of a true casting. The company asserts that this process produces parts at a cost up to 10 times lower than direct metal 3D printing methods, using standard casting alloys instead of expensive metal powders.

MetalMaker targets manufacturers who require functional metal prototypes and low-volume production runs. Initially, the business model focused on a rapid prototyping service for on-demand parts, starting with aluminum alloys like 356, which is common in the aerospace and automotive industries. The company is evolving to also sell small-scale foundry systems directly to manufacturers, enabling them to bring the custom metal part production process in-house and create parts in under 24 hours. Its services also include an online casting service where customers can upload 3D models to receive quotes and order parts with volume discounts available.

The MetalMaker System is designed for scalability, featuring a modular design that facilitates parallel manufacturing for both prototyping and volume production. It can produce parts up to 1,000 x 1,000 x 1,000 mm with a maximum volume of 15,000 cm³. A key component of their offering is an AI-powered software for pattern design generation, which streamlines the initial phase of the production workflow.