Blue Origin collaborates with Auburn University’s NCAME to advance copper 3D printing, addressing technical hurdles for aerospace applications.
Blue Origin has partnered with Auburn University’s National Center for Additive Manufacturing Excellence (NCAME) to address ongoing issues with copper 3D printing which is pivotal for aerospace manufacturing. This collaboration also encompasses the donation of two EOS M290 3D printers to NCAME that are purposed towards improving the processes for working with copper alloys GRCop-42 which has numerous applications in spaces of high temperatures.
Due to its high reflectivity and thermal conductivity, copper’s material properties considerably impede its use in additive manufacturing. The difficulty of melting copper powder with laser systems stems from the wide reflection of laser energy. Moreover, heat dissipation makes bonding even more problematic, resulting in unstable melt pools which create defects in the final parts. “Specialized laser systems are often needed to process copper effectively, but alloys like GRCop-42 can be printed using standard IRF lasers,” stated Jonathan Pegues, an NCAME research scientist.
The donated EOS M290 printers, already in use at NCAME, will accelerate research into optimizing GRCop-42 for Blue Origin’s needs. Nima Shamsaei, NCAME director, emphasized the partnership’s goal: “This collaboration bridges applied research with industry requirements, advancing solutions for durable, high-performance copper components.”
The shift towards the adoption of copper 3D printing stems from its capacity to mitigate the material cost and waste generated, lower expenses in cases of minimal production, and fabricate complex shapes that would be impossible to achieve using conventional manufacturing processes. Innovations extend beyond Blue Origin’s efforts: Nikon SLM Solutions recently developed pre-configured parameters for NASA’s GRCop-42, achieving 99.97% density in large-format 3D printers. Meanwhile, Eplus3D showcased red-laser technology at TCT Asia 2025, producing meter-scale copper parts without major hardware changes—addressing reflectivity and conductivity hurdles.
Such enhancements augur well for expanded uses in copper-stable, high-conductivity parts for aerospace, automotive, and electronics industries. For Blue Origin, advances in the additive building of custom copper pieces could improve thermal control and engine systems in rockets, which correspond to the firm’s enduring objectives concerning reusable space vehicles.
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This collaboration highlights a shift trend oriented towards academic-business interactions for dealing with the technological challenges in advanced manufacturing. These initiatives underscore copper alloys as crucial components for the next generation of aerospace engineering as the need for strong, yet light materials increases.
