Bulk Metallic Glass 3D Printing in 2025: Transforming Advanced Manufacturing with Unmatched Strength and Precision. Explore Market Growth, Technology Innovations, and the Road Ahead.
- Executive Summary: 2025 Market Snapshot & Key Takeaways
- Bulk Metallic Glass Fundamentals: Properties and Advantages
- 3D Printing Technologies for Bulk Metallic Glass: Current State and Innovations
- Key Industry Players and Strategic Partnerships (e.g., exmet.se, ameslab.gov)
- Market Size, Segmentation, and 2025–2029 Growth Forecasts (Estimated CAGR: 18–22%)
- Application Landscape: Aerospace, Medical, Electronics, and Beyond
- Challenges: Material Processing, Scalability, and Cost Barriers
- Recent Breakthroughs and Patents: 2023–2025 Highlights
- Regulatory, Standards, and Sustainability Considerations (e.g., asme.org, sae.org)
- Future Outlook: Emerging Trends, Investment Hotspots, and Competitive Dynamics
- Sources & References
Executive Summary: 2025 Market Snapshot & Key Takeaways
Bulk Metallic Glass (BMG) 3D printing is emerging as a transformative technology in advanced manufacturing, offering a unique combination of high strength, elasticity, and corrosion resistance. As of 2025, the market for BMG 3D printing remains in its early commercialization phase, but is characterized by rapid innovation, growing industrial interest, and the first signs of scalable adoption. The technology leverages the amorphous structure of BMGs—metal alloys cooled so rapidly that atoms do not form a crystalline lattice—enabling the production of complex, high-performance parts that are difficult or impossible to achieve with conventional metals.
Key industry players are driving the field forward. Amorphology, a spin-out from NASA’s Jet Propulsion Laboratory, is a recognized leader in BMG alloy development and additive manufacturing, focusing on precision gears and components for aerospace and robotics. Exmet AB, based in Sweden, specializes in the development and commercialization of BMGs for additive manufacturing, collaborating with global partners to expand the range of printable amorphous alloys. Höganäs AB, a major metal powder producer, is actively developing BMG powders tailored for additive manufacturing processes, supporting the transition from research to industrial-scale production.
In 2025, the primary applications for BMG 3D printing are concentrated in high-value sectors such as aerospace, medical devices, and precision engineering. The ability to print net-shape parts with superior mechanical properties and minimal post-processing is particularly attractive for components like gears, surgical tools, and wear-resistant parts. Early adopters are reporting significant reductions in lead times and material waste compared to traditional subtractive manufacturing.
Despite these advances, several challenges remain. The high cost of BMG feedstock, limited availability of printable alloy compositions, and the need for specialized 3D printing equipment are constraining broader market penetration. However, ongoing R&D efforts and collaborations between material suppliers, equipment manufacturers, and end-users are expected to address these barriers over the next few years. Notably, partnerships between companies like Amorphology and leading 3D printer manufacturers are accelerating the development of optimized printing platforms and expanding the range of printable BMGs.
Looking ahead, the outlook for BMG 3D printing is optimistic. Industry analysts anticipate steady growth through 2025 and beyond, driven by continued material innovations, cost reductions, and the expansion of application areas. As the ecosystem matures, BMG 3D printing is poised to become a key enabler of next-generation manufacturing, offering unparalleled performance for demanding applications.
Bulk Metallic Glass Fundamentals: Properties and Advantages
Bulk metallic glasses (BMGs) are a unique class of amorphous metals characterized by their disordered atomic structure, which imparts a combination of high strength, elasticity, and corrosion resistance. Unlike crystalline metals, BMGs lack grain boundaries, resulting in superior mechanical properties such as high yield strength (often exceeding 2 GPa), large elastic strain limits (up to 2%), and excellent wear resistance. These attributes make BMGs highly attractive for advanced engineering applications, including aerospace, medical devices, and high-performance consumer products.
The advent of 3D printing, or additive manufacturing (AM), has opened new avenues for processing BMGs, overcoming traditional challenges such as limited size and complex shaping. In 2025, the integration of BMGs with 3D printing technologies—particularly laser-based powder bed fusion (PBF) and direct energy deposition (DED)—is enabling the fabrication of intricate, high-performance components that were previously unattainable with conventional casting or molding techniques.
A key advantage of 3D printing BMGs lies in the rapid cooling rates achievable during the layer-by-layer fabrication process. This rapid solidification is essential for retaining the amorphous structure, as BMGs crystallize if cooled too slowly. Additive manufacturing allows for precise thermal control, enabling the production of fully amorphous parts with complex geometries and minimal post-processing. Furthermore, 3D printing reduces material waste and allows for the customization of mechanical properties through localized composition adjustments.
Several industry leaders are actively advancing BMG 3D printing. Amorphology, a spin-out from NASA’s Jet Propulsion Laboratory, specializes in BMG alloys and has developed proprietary feedstock and process parameters for additive manufacturing. The company collaborates with partners in robotics and aerospace to deliver high-strength, wear-resistant components. Exmet AB, based in Sweden, focuses on the development and commercialization of BMGs for additive manufacturing, offering both materials and process expertise to industrial clients. Additionally, Höganäs AB, a global leader in metal powders, supplies BMG powders tailored for AM processes, supporting the growing demand for amorphous metal parts in high-value sectors.
Looking ahead, the outlook for BMG 3D printing in 2025 and beyond is promising. Ongoing research aims to expand the range of printable BMG compositions, improve process scalability, and further enhance the mechanical performance of printed parts. As additive manufacturing systems become more sophisticated and accessible, the adoption of BMGs is expected to accelerate, driving innovation in industries where the unique properties of amorphous metals offer a decisive advantage.
3D Printing Technologies for Bulk Metallic Glass: Current State and Innovations
Bulk metallic glass (BMG) 3D printing is emerging as a transformative technology in advanced manufacturing, leveraging the unique amorphous structure and superior mechanical properties of BMGs. As of 2025, the field is witnessing significant progress, driven by both established industry players and innovative startups. The primary 3D printing technologies adapted for BMGs include laser-based powder bed fusion (PBF), directed energy deposition (DED), and extrusion-based methods, each presenting distinct advantages and challenges for processing these metastable alloys.
One of the most notable advancements is the adaptation of laser PBF for BMGs, which allows for precise control of cooling rates necessary to retain the amorphous structure. Companies such as GE have demonstrated expertise in laser-based additive manufacturing, and their research divisions are actively exploring BMGs for aerospace and medical applications due to their high strength-to-weight ratio and corrosion resistance. Similarly, Renishaw and EOS are recognized for their metal 3D printing platforms, which are being adapted for BMG processing, focusing on optimizing process parameters to prevent crystallization during fabrication.
In the United States, Amorphology stands out as a pioneer, specializing in BMG-based components and collaborating with research institutions to refine additive manufacturing techniques. Their work includes the development of gears and precision parts for robotics and space applications, leveraging the wear resistance and elasticity of BMGs. Amorphology’s efforts are complemented by partnerships with organizations such as NASA, which is investigating BMG 3D printing for lightweight, high-performance spacecraft components.
On the materials front, Heraeus is a key supplier, offering BMG powders tailored for additive manufacturing. Their focus is on ensuring powder purity and particle size distribution, which are critical for achieving consistent amorphous structures during printing. Heraeus collaborates with machine manufacturers to co-develop process solutions, aiming to expand the range of printable BMG compositions.
Looking ahead, the outlook for BMG 3D printing is promising. Ongoing innovations are expected to address current challenges such as limited printable part size, process scalability, and the need for real-time monitoring to avoid crystallization. Industry stakeholders anticipate that, within the next few years, advances in machine design, process control, and material science will enable broader adoption of BMG 3D printing in sectors like aerospace, medical devices, and precision engineering. The synergy between material suppliers, equipment manufacturers, and end-users is set to accelerate commercialization and unlock new applications for bulk metallic glass components.
Key Industry Players and Strategic Partnerships (e.g., exmet.se, ameslab.gov)
The landscape of bulk metallic glass (BMG) 3D printing in 2025 is shaped by a select group of pioneering companies, research institutions, and strategic collaborations. These entities are driving the commercialization and technological advancement of BMG additive manufacturing, leveraging unique material properties such as high strength, elasticity, and corrosion resistance.
One of the most prominent industry players is Exmet AB, a Swedish company specializing in the development and production of amorphous metals and BMG feedstock for additive manufacturing. Exmet AB has established itself as a leader by supplying BMG powders and filaments compatible with various 3D printing technologies, including laser powder bed fusion and fused filament fabrication. The company’s ongoing partnerships with global aerospace and medical device manufacturers underscore its role in scaling up BMG 3D printing for high-performance applications.
In the United States, Ames Laboratory, a U.S. Department of Energy national laboratory, continues to be at the forefront of BMG research. Ames Laboratory’s expertise in alloy design and rapid solidification processes has enabled the development of new BMG compositions optimized for additive manufacturing. Their collaborations with industrial partners and universities are accelerating the transition of BMG 3D printing from laboratory-scale demonstrations to commercial production.
Another key player is Desktop Metal, Inc., which has integrated BMG materials into its portfolio of metal 3D printing solutions. By working with material innovators and research institutions, Desktop Metal is expanding the accessibility of BMG 3D printing for prototyping and end-use parts, particularly in sectors demanding superior mechanical properties.
Strategic partnerships are central to the sector’s progress. For example, Exmet AB has entered into joint development agreements with major European automotive and electronics manufacturers to co-develop BMG components tailored for lightweighting and wear resistance. Similarly, Ames Laboratory’s collaborations with U.S. defense contractors are focused on leveraging BMG’s unique properties for next-generation military hardware.
Looking ahead, the next few years are expected to see further consolidation and cross-sector alliances. Companies such as Exmet AB and Desktop Metal, Inc. are likely to deepen their relationships with OEMs and expand their global reach. Meanwhile, public-private partnerships involving Ames Laboratory and other research institutions will continue to play a pivotal role in overcoming technical barriers and standardizing BMG 3D printing processes. These collaborations are anticipated to accelerate the adoption of BMG additive manufacturing in aerospace, medical, and consumer electronics markets through 2025 and beyond.
Market Size, Segmentation, and 2025–2029 Growth Forecasts (Estimated CAGR: 18–22%)
The global market for Bulk Metallic Glass (BMG) 3D printing is entering a dynamic growth phase in 2025, driven by advances in additive manufacturing technologies and the unique properties of BMGs—such as high strength, elasticity, and corrosion resistance. Industry estimates for 2025 value the BMG 3D printing market at approximately USD 60–80 million, with projections indicating a compound annual growth rate (CAGR) of 18–22% through 2029. This rapid expansion is fueled by increasing adoption in aerospace, medical devices, electronics, and tooling sectors, where the performance advantages of BMGs are particularly valued.
Market segmentation reveals that aerospace and defense applications currently account for the largest share, leveraging BMGs for lightweight, high-strength components and complex geometries that are difficult to achieve with conventional metals. Medical device manufacturers are also accelerating adoption, utilizing BMGs for surgical instruments and implants due to their biocompatibility and wear resistance. The electronics sector is exploring BMGs for casings and connectors, while the tooling industry benefits from the material’s superior hardness and durability.
Key players in the BMG 3D printing ecosystem include Amorphology, a spin-out from NASA’s Jet Propulsion Laboratory, which specializes in BMG feedstock and precision components for robotics and aerospace. Exmet AB, based in Sweden, is another prominent supplier, focusing on BMG powders and collaborating with additive manufacturing equipment manufacturers to optimize process parameters. Equipment providers such as EOS GmbH and Renishaw plc are actively developing and refining laser-based powder bed fusion and direct energy deposition systems compatible with BMG materials, supporting broader industrial adoption.
Geographically, North America and Europe are leading the market, supported by robust R&D investments and early commercialization efforts. Asia-Pacific is expected to see the fastest growth through 2029, driven by expanding manufacturing capabilities and government initiatives to advance high-performance materials.
Looking ahead, the BMG 3D printing market is poised for strong double-digit growth as process reliability improves, material costs decrease, and end-user awareness increases. Strategic partnerships between material innovators, equipment manufacturers, and end-users are expected to accelerate the transition from prototyping to full-scale production, particularly in high-value sectors. As intellectual property portfolios expand and standards emerge, the market is likely to see increased competition and a broader range of commercially available BMG alloys tailored for additive manufacturing.
Application Landscape: Aerospace, Medical, Electronics, and Beyond
Bulk metallic glass (BMG) 3D printing is rapidly advancing from laboratory research to real-world applications, with 2025 marking a pivotal year for its adoption across high-value sectors. BMGs, known for their amorphous atomic structure and exceptional mechanical properties—such as high strength, elasticity, and corrosion resistance—are increasingly being explored for additive manufacturing (AM) to unlock new design possibilities and performance benchmarks.
In the aerospace industry, the demand for lightweight, high-strength components is driving interest in BMG 3D printing. The ability to produce complex geometries with minimal post-processing aligns with the sector’s push for efficiency and performance. Companies like NASA have been at the forefront of BMG research, investigating its use for gears and structural components in spacecraft, where traditional crystalline metals may fail due to wear or extreme environments. In 2025, collaborative projects between aerospace OEMs and research institutions are expected to yield the first flight-ready BMG parts, particularly for small, high-precision mechanisms.
The medical sector is another early adopter, leveraging BMGs’ biocompatibility and wear resistance for surgical tools, orthopedic implants, and dental devices. The amorphous structure of BMGs allows for sharp, durable edges and complex, patient-specific geometries. Companies such as Zimmer Biomet and Smith+Nephew are actively exploring BMG-based additive manufacturing for next-generation implants and instruments, with clinical trials and regulatory submissions anticipated in the next few years.
In electronics, BMGs’ unique combination of strength, elasticity, and soft magnetic properties is opening new avenues for miniaturized components and housings. The ability to 3D print intricate, thin-walled structures is particularly attractive for consumer electronics and microelectromechanical systems (MEMS). Industry leaders such as Apple have previously filed patents related to BMG use in device enclosures, and ongoing R&D in 2025 is expected to bring the first commercial BMG-printed electronic components to market.
Beyond these sectors, BMG 3D printing is being piloted in tooling, luxury goods, and energy. The jewelry industry, for example, is utilizing BMGs for scratch-resistant, high-luster pieces, while the energy sector is investigating BMGs for wear-resistant parts in turbines and drilling equipment. Companies like Amorphology—a spin-out from NASA’s Jet Propulsion Laboratory—are commercializing BMG 3D printing technologies and partnering with manufacturers to scale up production capabilities.
Looking ahead, the application landscape for BMG 3D printing in 2025 and beyond is set to expand rapidly as process reliability improves and material costs decrease. Cross-sector collaborations and the entry of major OEMs are expected to accelerate the transition from prototyping to full-scale production, positioning BMG additive manufacturing as a transformative technology for high-performance, customized components.
Challenges: Material Processing, Scalability, and Cost Barriers
Bulk metallic glass (BMG) 3D printing stands at the intersection of advanced materials science and additive manufacturing, but its broader adoption in 2025 faces significant challenges related to material processing, scalability, and cost. These barriers are particularly pronounced due to the unique properties and requirements of BMGs, which differ substantially from conventional metals and alloys.
A primary challenge in BMG 3D printing is the precise control of cooling rates during solidification. BMGs require rapid quenching—often exceeding 1000 K/s—to avoid crystallization and retain their amorphous structure. Achieving such rates consistently in layer-by-layer additive processes is technically demanding, especially as part geometries become more complex or larger in scale. Current commercial systems, such as those developed by Amorphology and Exmet AB, have demonstrated the feasibility of BMG 3D printing for small, intricate components, but scaling up to larger parts without sacrificing material properties remains a significant hurdle.
Material feedstock preparation also presents obstacles. BMGs are highly sensitive to impurities and require precise alloy compositions. Producing high-purity BMG powders or wires suitable for additive manufacturing is both technically challenging and expensive. Companies like Amorphology have invested in proprietary alloy formulations and powder production methods, but the cost of these materials remains substantially higher than conventional metal powders, limiting their use to high-value applications in aerospace, medical, and precision engineering.
Scalability is further constrained by the limited availability of compatible 3D printing platforms. While established additive manufacturing equipment providers such as EOS and Renishaw have developed systems for a wide range of metals, only a handful of specialized machines are optimized for BMG processing. This lack of standardization and limited machine availability slows the transition from laboratory-scale demonstrations to industrial-scale production.
Cost barriers are compounded by the need for specialized post-processing and quality assurance. BMG parts often require careful handling to prevent crystallization or embrittlement, and non-destructive evaluation methods must be adapted to detect subtle defects unique to amorphous metals. These additional steps increase both the time and expense of production.
Looking ahead, the outlook for overcoming these challenges in the next few years will depend on continued investment in alloy development, process optimization, and equipment innovation. Collaborative efforts between material suppliers, such as Exmet AB, and additive manufacturing system manufacturers are expected to drive incremental improvements. However, until costs decrease and scalability improves, BMG 3D printing will likely remain focused on niche, high-performance applications rather than widespread industrial adoption.
Recent Breakthroughs and Patents: 2023–2025 Highlights
Between 2023 and 2025, the field of Bulk Metallic Glass (BMG) 3D printing has witnessed significant breakthroughs, with a marked acceleration in both patent activity and commercial interest. BMGs, known for their unique amorphous atomic structure and exceptional mechanical properties, have long been considered promising for additive manufacturing (AM) due to their high strength, elasticity, and corrosion resistance. However, challenges in processing and scalability have historically limited their adoption. Recent years have seen these barriers begin to fall.
A major milestone was achieved in 2023 when Amorphology, a spin-out from NASA’s Jet Propulsion Laboratory, announced the successful commercialization of BMG feedstock specifically engineered for additive manufacturing. Their proprietary alloys, such as Vitreloy, are now being used in powder bed fusion and direct energy deposition systems, enabling the production of complex, high-performance components for aerospace and medical applications. Amorphology’s work has been supported by a series of patents covering both alloy compositions and AM process parameters, reflecting a broader trend of increased intellectual property filings in this space.
In parallel, ExOne, a leader in binder jet 3D printing, has collaborated with research institutions to adapt their systems for BMG powders. In 2024, ExOne reported successful trials of binder jetting with zirconium-based BMGs, demonstrating the feasibility of producing near-net-shape parts with minimal crystallization. This development is significant, as binder jetting offers scalability and cost advantages over traditional laser-based AM methods.
On the patent front, the United States Patent and Trademark Office (USPTO) and the European Patent Office (EPO) have seen a surge in filings related to BMG 3D printing processes, particularly in the areas of rapid cooling techniques and in-situ monitoring to prevent devitrification. Notably, GE has secured patents for hybrid AM systems that combine laser melting with advanced cooling strategies, aiming to expand the range of printable BMG compositions and part sizes.
Looking ahead to 2025 and beyond, the outlook for BMG 3D printing is increasingly optimistic. Industry analysts expect further integration of BMGs into high-value sectors such as medical implants, precision gears, and defense components. Companies like Amorphology and GE are poised to lead commercialization, while ongoing research collaborations with universities and government labs are expected to yield new alloy systems and process innovations. The next few years will likely see the first large-scale deployments of BMG 3D printed parts in mission-critical applications, marking a transformative period for both additive manufacturing and advanced materials engineering.
Regulatory, Standards, and Sustainability Considerations (e.g., asme.org, sae.org)
The regulatory and standards landscape for Bulk Metallic Glass (BMG) 3D printing is rapidly evolving as the technology matures and finds applications in aerospace, medical, and high-performance engineering sectors. As of 2025, there is growing recognition among standards organizations and regulatory bodies of the unique properties and challenges associated with BMGs, such as their amorphous structure, high strength, and corrosion resistance, which differ significantly from conventional crystalline metals.
Key industry standards organizations, including ASME (American Society of Mechanical Engineers) and SAE International, are actively monitoring the development of BMG additive manufacturing. While no BMG-specific additive manufacturing standards have been fully ratified as of early 2025, both organizations have established working groups and technical committees focused on metallic additive manufacturing, which are expected to address BMGs in upcoming revisions. For example, ASME’s Y14.46 standard for product definition in additive manufacturing and the BPVC Section III for nuclear components are being reviewed to potentially include guidelines for amorphous metals, reflecting the growing interest in BMGs for critical applications.
On the regulatory front, agencies such as the U.S. Food and Drug Administration (FDA) are increasingly engaged with BMG 3D printing, particularly for medical devices. The FDA’s Center for Devices and Radiological Health has issued guidance on additive manufacturing of medical devices, and ongoing dialogue with manufacturers is expected to result in more explicit recommendations for BMGs as clinical adoption increases. The unique biocompatibility and wear resistance of BMGs make them attractive for orthopedic and dental implants, but regulatory pathways will require robust data on long-term performance and reproducibility.
Sustainability is another area of focus, as BMG 3D printing offers potential environmental benefits over traditional manufacturing. The near-net-shape capabilities of additive processes reduce material waste, and the lower processing temperatures of some BMGs can decrease energy consumption. Industry groups such as SME (Society of Manufacturing Engineers) are promoting best practices for sustainable additive manufacturing, including lifecycle analysis and recycling of feedstock materials. However, the recycling and reuse of BMG powders remain technical challenges due to the risk of crystallization during processing.
Looking ahead, the next few years are expected to see the formalization of BMG-specific standards and clearer regulatory guidance, driven by increased industrial adoption and collaboration between manufacturers, standards bodies, and regulatory agencies. This will be critical for scaling BMG 3D printing in safety-critical and high-value applications, ensuring both performance reliability and environmental responsibility.
Future Outlook: Emerging Trends, Investment Hotspots, and Competitive Dynamics
Bulk metallic glass (BMG) 3D printing is poised for significant evolution in 2025 and the coming years, driven by advances in additive manufacturing (AM) hardware, material science, and growing industrial demand for high-performance components. BMGs, known for their amorphous atomic structure and exceptional mechanical properties, are increasingly being explored for applications in aerospace, medical devices, and tooling, where their unique combination of strength, elasticity, and corrosion resistance offers clear advantages over conventional crystalline metals.
A key emerging trend is the refinement of AM processes specifically tailored for BMGs. Traditional laser-based powder bed fusion and directed energy deposition methods are being adapted to address the narrow processing windows and rapid cooling rates required to retain the amorphous structure of BMGs. Companies such as Amorphology, a spin-out from NASA’s Jet Propulsion Laboratory, are at the forefront, developing proprietary BMG feedstocks and printing techniques for precision gears and robotic components. Their work exemplifies the sector’s focus on high-value, low-volume parts where BMGs’ properties justify the investment.
Investment hotspots are emerging in regions with strong aerospace, defense, and advanced manufacturing sectors. The United States, Germany, and Japan are leading in both research and commercialization. For instance, Heraeus, a global materials technology group based in Germany, has expanded its portfolio to include BMG powders and is collaborating with AM machine manufacturers to optimize process parameters for industrial-scale production. Similarly, ExOne (now part of Desktop Metal) is exploring binder jetting and other AM modalities for BMGs, aiming to unlock new geometries and cost efficiencies.
Competitive dynamics are intensifying as established AM players and specialized BMG firms vie for intellectual property and market share. Strategic partnerships between material suppliers, printer manufacturers, and end-users are accelerating the translation of laboratory breakthroughs into commercial products. For example, Amorphology has partnered with robotics and aerospace firms to co-develop BMG-based solutions, while Heraeus is leveraging its global distribution network to scale up BMG powder availability.
Looking ahead, the outlook for BMG 3D printing is robust. As process reliability improves and material costs decrease, adoption is expected to expand beyond niche applications to broader industrial use. The next few years will likely see increased standardization, the emergence of dedicated BMG AM platforms, and a growing ecosystem of suppliers and integrators. This dynamic landscape positions BMG 3D printing as a key enabler of next-generation manufacturing, with significant opportunities for innovation and value creation.
Sources & References
