Advanced manufacturing often pits disruptive technologies against traditional methods, framing them as competitors rather than collaborators. However, the true power of additive manufacturing (AM) lies not in replacing established processes but in augmenting them. A groundbreaking collaboration between design consultancy Metamorphic AM and casting specialist Sylatech exemplifies this philosophy. Their work on a high-performance static mixer demonstrates how computational design and investment casting can combine to scale intricate geometries from prototype to mass production—without sacrificing performance, cost efficiency, or sustainability.
This partnership redefines AM as a catalyst rather than an endpoint—a tool that enhances conventional manufacturing by unlocking new design possibilities and production efficiencies.
Computational Design: From Fluid Dynamics to Castable Geometry
At the heart of this project was a braided static mixer, engineered to function as a high-efficiency heat exchanger. The mixer’s role was to blend viscous, often immiscible fluids through a complex flow path that maximizes thermal transfer while minimizing pressure drop.
Using computational fluid dynamics (CFD) and topology optimization, Metamorphic generated a geometry that:
Maximized surface-area-to-volume ratio for enhanced heat exchange
Minimized turbulence and pressure loss
Ensured self-supporting structures for manufacturability
Unlike traditional designs constrained by machining limitations, this algorithmically optimized geometry was born from functional intent—every twist and turn served a purpose.
Bridging AM and Investment Casting for Scalability
Initially prototyped via Direct Metal Laser Sintering (DMLS), the mixer could be produced at a rate of ~50 units/day. However, projected demand required thousands per day, making pure AM impractical for mass production.
Sylatech’s MorphoCast process provided the solution—a hybrid workflow combining:
AM-produced patterns (via Photocentric for precision, Voxeljet for larger parts)
Plaster-based investment casting with vacuum-assisted filling
Ceramic filters (60PPI) to reduce turbulence and vortex traps to capture oxides
The result? Production surged to 1,800 units/day in aluminium A356 and aluminium-bronze AB1, with wall thicknesses as fine as 0.4 mm.
Simulation-Driven Design for Manufacturability
A key success factor was early integration of casting considerations into the computational design phase. Metamorphic and Sylatech employed:
Metal flow simulations to optimize runner systems
Thermal modeling to predict solidification defects
Parametric design adjustments to ensure self-supporting structures
This iterative feedback loop between digital design and physical production prevented common AM-to-casting pitfalls, ensuring defect-free replication of intricate internal channels.
Sustainable High-Performance: The Hybrid Advantage
Beyond scalability, this hybrid approach delivered sustainability benefits:
Use of 85% post-consumer recycled aluminium, enabled by Sylatech’s MeltX purification tech
Material efficiency from near-net-shape casting vs. subtractive machining
Energy savings by avoiding pure AM’s layer-by-layer process
The project also demonstrated how hybrid manufacturing simplifies qualification pathways for regulated industries by leveraging:
Certified casting materials
Established inspection protocols (CT scanning, dye penetrant)
Mature supply chains
Conclusion: A New Paradigm for Manufacturing
The Metamorphic-Sylatech collaboration proves that the future of manufacturing isn’t additive OR traditional—it’s additive AND traditional. By treating AM as an enabler of casting rather than its replacement, they achieved:
Uncompromised design complexity
Mass-production scalability
Superior sustainability
This hybrid manufacturing blueprint extends far beyond heat exchangers—it’s a replicable model for aerospace components, automotive systems, and energy infrastructure. As industries seek to balance innovation with scalability, such technology-agnostic approaches will define the next era of production.
