A team of researchers has found a new way to manufacture one of the toughest materials used in industry, opening the door to cheaper, more efficient production of high-performance tools.
The material, called tungsten carbide–cobalt (WC–Co), is extremely hard and resistant to wear, which makes it ideal for cutting tools, mining equipment, and construction machinery.
However, that same toughness also makes it very difficult and expensive to shape using traditional methods.
Currently, WC–Co is produced through powder metallurgy, a process that compresses powders of tungsten carbide and cobalt under very high pressure and heat.
While this method creates strong products, it uses large amounts of costly raw materials and often results in significant waste.
Because tungsten and cobalt are expensive, manufacturers have long been searching for a more economical approach.
Researchers from Hiroshima University and industry partners have now demonstrated that advanced 3D printing can produce this material while maintaining its strength and durability.
Their study, published in the International Journal of Refractory Metals and Hard Materials, used a specialized technique called hot-wire laser irradiation.
This method combines a powerful laser with a preheated metal wire, allowing material to be deposited precisely where needed.
Unlike many metal 3D printing methods that completely melt the material, the new approach softens the metals just enough to shape them without losing their structure.
By carefully controlling temperature, the team prevented damage that can occur when the material overheats. This technique also reduced the risk of defects that typically weaken 3D-printed metals.
The researchers tested two fabrication strategies.
In one method, the cemented carbide rod guided the process, while in the other the laser led the movement. Both approaches aimed to build the material layer by layer onto an iron base.
Although each method had challenges, the team improved the process by adding a thin layer of nickel alloy between materials and carefully managing heat levels.
The final results were impressive. The 3D-printed material achieved hardness values above 1400 HV, placing it among the hardest substances used in industrial applications, just below materials like sapphire and diamond.
Importantly, the printed components showed no major defects, demonstrating that the method can produce industrial-grade quality.
Because additive manufacturing allows material to be placed only where it is needed, the process can significantly reduce waste and cost. This could make it easier to produce customized tools and parts while conserving valuable resources. The ability to manufacture complex shapes is another advantage, since traditional methods struggle to create intricate designs from such hard materials.
The researchers say the technique could eventually be used not only for cutting tools but also for other advanced components that require extreme durability. Future work will focus on preventing cracks, improving reliability, and exploring applications with other difficult-to-manufacture materials.
If successfully developed for large-scale production, this breakthrough could transform how some of the world’s toughest industrial materials are made.
By combining precision 3D printing with innovative heat control, scientists are turning what was once nearly impossible to shape into something that can be manufactured more efficiently, potentially reshaping industries that rely on ultra-hard materials.
