Breaking Free from Conventional Manufacturing

Traditional methods — such as machining, casting or forging — have long been the standard in manufacturing. While these approaches have proven reliable and offer certain advantages, they also come with limitations in shape and material selection.

This is where additive manufacturing (AM), also known as metal 3D printing, enters the picture, building objects layer by layer from digital designs.

The technology is gaining attention for its unparalleled design freedom. With additive manufacturing, even complex shapes — such as hollow structures, lattices, and curves — that previously had to be produced in separate parts can now be printed as a single piece. By combining lightness with high strength, this approach offers a significant advantage in industries where weight and fuel efficiency are critical, especially in aerospace.

Accelerating the Metal 3D Printing Business

Metal 3D printers are making an impact across many industries — from aerospace and energy to automotive and healthcare. Among these, the aerospace sector has become the main focus for both the AM market and Nikon itself.
The demand for small satellites is growing rapidly, with parts of around 300mm^* in size becoming standard. As the aerospace industry evolves, the need for even larger, higher-volume components is expected to rise.

• *In general, objects with a depth, width, and height exceeding 300mm are considered large-scale prints.

Taking Nikon's AM Technology into Space

When it comes to metal 3D printing, there are various methods, with Nikon employing two main approaches.

The first is Direct Energy Deposition (DED). In this method, a laser melts a base material to create a melt pool, into which metal powder is injected and solidified layer by layer. Because it can directly deposit metal onto an existing part, DED is especially suited for repairing worn components, modifying shapes, and hardfacing.

The second is Laser-Powder Bed Fusion (L-PBF). This process spreads a thin layer of metal powder, then selectively melts only the necessary areas with lasers. The cycle of layering and melting is repeated until the full structure is complete. This is the approach that Nikon is currently focusing on.

Nikon originally developed DED systems, but with the acquisition of Nikon SLM Solutions, the company added L-PBF systems to its lineup — covering more than 70% of the market. These L-PBF systems not only handle complex shapes once deemed impossible but can also produce parts as large as 600 x 600 x 1500mm. They enable the production of 3D lattice structures, achieving groundbreaking weight reduction while maintaining structural integrity — a crucial advantage in aerospace applications.

And Nikon doesn't stop there. Its systems incorporate the world's first multi-laser system for high-speed printing, with up to 12 lasers working simultaneously — delivering both greater mass-production capability and the fine detail only lasers can achieve. This technology also eliminates the need for casting molds, thereby shortening lead times, and makes it possible to print difficult materials, such as nickel-based alloys, into complex shapes.

Most importantly, adding L-PBF systems has allowed Nikon to deepen its commitment to the space industry, where demand is growing for large, high-quality, complex parts that must perform in extreme environments. The advantages of the PBF method mentioned earlier come into play here.

Nikon is already exploring potential applications for parts created with metal 3D printers, such as producing rocket components, while also contributing to space projects through its long-standing supply of cameras to the International Space Station (ISS). Recognizing the capabilities of its metal 3D printers, Nikon's 3D printing technology has been selected for the Japan Aerospace Exploration Agency (JAXA) Space Strategy Fund program. This project is steadily progressing toward the goal of reducing launch costs by developing lighter, higher-performance spacecraft, and by shortening production and development timelines. Nikon's role is to establish metal 3D printing technologies that combine both DED and PBF methods, enabling the production of large, high-precision components for rockets. This challenge is only just beginning for Nikon.

And beyond aerospace, the impact of metal 3D printing reaches much further throughout society. By reducing the number of processes, consolidating production, saving energy, and minimizing waste through repair and reuse, Nikon's technology is helping to drive much more sustainable manufacturing for the future.

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Expanding the Possibilities of Manufacturing with People and Technology

Nikon's strength lies in its ability to offer a wide range of solutions tailored to each customer's needs. From the Nikon AM Technology Centers, we are increasing opportunities to engage directly with customers more than ever, and using our unique technologies to drive innovation across industries — from aerospace to many others.

I joined Nikon around the time this business was launched, stepping into a role in business development, where I focus on planning, marketing, and sales activities. What I find most exciting is the chance to work in a startup-like way, even within Nikon's established organizational structure.

Building the metal 3D printing business in Japan comes with its challenges. One is fostering a new design mindset: showing customers that it's now possible to create things that were previously impossible, or to dramatically improve efficiency through fresh design approaches. Another is creating an environment where customers can quickly experience the value of the technology firsthand.

That's why we stay close to the customers right in front of us, delivering what we can, when we can. Our mission is to understand their work deeply and support them from the design stage onward, walking alongside them as true partners. This is at the heart of what we do.