Experimental Version (Beta) – Available Now!
The Mk1 Experimental represents a revolutionary advance in 3D printing — bringing to life new possibilities for metal additive manufacturing. Centered on our patented MagnetoJet technology, the Mk1 propels liquefied metal from a 1200°C chamber encased in an electromagnetic field through print nozzles similar to an inkjet printer — allowing full control of the Earth’s most abundant metal, aluminum. Its reliance on wire feedstock rather than powders allows the Mk1 to offer significantly reduced operating expenses and dramatically reduced time for near net shape parts. This remarkable step in technology is delivered through a state of the art touchscreen user interface, with access to all process parameters — ideal for research and development applications.
Mk1 Production-Grade System: Coming 2018
Our production grade version, slated for 2018 release, will offer all of this and more: production-stable capability for short run and specialty production items, additional printable materials such as bronze and copper, and advanced touchscreen software that creates an intuitive experience.
Technology Readiness Level: 5
Technology Readiness Level (TRL) is a system developed by NASA to rate a technology’s maturation, and show how close the technology is to complete commercialization / production stability. The scale runs from 1 to 9, where 9 is ready for mass deployment. At Vader Systems, our desire is to remain transparent to our customers. In acknowledging where we are in the process, we also reaffirm our commitment to achieving process maturation in the shortest possible time. We recognize many are eager to get printing!
12” x 12” x 12”
(300 mm x 300 mm x 300 mm)
Aluminum and its alloys
(4043, 6061, 7075)
200 to 500 micron
1 lb per hour based on 500 micron droplet size
Speed vs Powder Bed Fusion
Part cost vs Powder Bed Fusion
Vader’s patent pending MagnetoJet technology is based on the study of Magneto Hydro Dynamics (MHD), or more simply: the manipulation of liquid metal through magnetism. MagnetoJet’s extraordinary physics are accomplished by depositing Aluminum wire into an 1200°C ceramic chamber, where it is influenced into a molten state. This molten media is then electromagnetically pulsed – causing a droplet to form and eject with precision from a carefully crafted ceramic nozzle.
The Mk1 delivers 1000 droplets per second with micron level accuracy, while doubling the speed of conventional 3D powder bed metal printers. Aluminum was an intentional first step, but MagnetoJet will evolve to printing additional conductive metals and potentially thousands of printing heads within one machine.
The next evolution—will contain 10 printing heads and produce parts 30x faster than the Mk1. Once this is realized, metallic design and manufacturing will be exponentially impacted across all industries.
Necessity… the mother of invention. – Plato
Quickly realizing that engineering school would not get interesting until his senior year in college, Zack Vader decided not to waste any time and began his life’s work in 2011 at the age of 18. His initial efforts culminated in the design of a micro-gas turbine generator. As he thought through the business case, he concluded that no one had produced something similar due to prohibitive manufacturing costs. In realizing that cost efficiency was on the critical path, Zack explored creating the turbine utilizing a cutting edge technology – 3D Metal Printing.
His creativity and ambition caught the attention of his father (Scott), who began to see the possibilities within Zack’s imaginative work. A 3D printing pioneer within the fiberglass industry, Scott found enjoyment in helping his son, and they utilized the latest turbine Computer Aided Design and Finite Element Analysis software to create a product that could potentially change the world.
After an extensive search, the father and son team located one provider of 3D Metal Printing within in the US, and upon learning about Vader’s product, the company quickly became an enthusiastic partner. Shortly before the first turbine was to enter production, General Electric acquired the 3D printing company and all outside capacity was taken offline. Discouraged, but still inspired, Scott and Zack went searching for another source. Zack and Scott’s necessity of finding a 3D Metal Printing supplier – and the lack of any viable options – led them to the idea of developing their own version.
It was at this time that Zack identified and merged two complimenting technologies for a new printer: Magneto Hydro Dynamics (MHD) & Liquid Metal Jet Printing (LMJP). Through this melding of MHD and LMJP, the MagnetoJet was born.
Beyond overseeing the innovation process at Vader, Scott’s career has led him to be a recognized expert in the additive composite manufacturing industry. He ran US operations for a large Canadian manufacturer and was responsible for all facets of the US business, including many engineering innovations. He has pioneered many virtual prototyping, CAE, CFD methods to generate industry-leading time to market for industrial products.
Chief Innovation Officer
From development of road skis, to IED blast injury prevention helmets, to liquid-cooled high performance gaming computers, Zack has a voracious drive to solve problems and improve the world. In designing a micro-gas turbine generator, Zack realized that the lack of accessible, low cost metal additive manufacturing technology was the major challenge to current industrial innovation. His vision of jet printing molten metals using MHD propulsion led to the inception of Vader Systems.