Russia Enters an Era of Additive Breakthroughs

Scientists in St. Petersburg Have Taught Metals to Work Together at the Microscale

Peter the Great St. Petersburg Polytechnic University (SPbPU) has delivered a technological breakthrough that could reshape Russia’s industrial landscape. Researchers at the Institute of Machinery, Materials, and Transport have developed a unique multi-material 3D-printing technology that makes it possible, within a single production cycle, to manufacture complex components from four different alloys, with smooth, gradient transitions between them at a scale of less than one millimeter.

Traditionally, multi-material components suffer from structural “weak points” – sharp interfaces between materials where stress concentrates, microcracks form, and defects emerge. SPbPU’s approach eliminates the interface itself. Instead of a joint, the technology creates a zone of gradual property change, where heat resistance, strength, elasticity, or biocompatibility are distributed precisely according to operating conditions. In laboratory tests, researchers have already validated more than 20 material combinations, including titanium and aluminum alloys as well as shape-memory materials.

One Part, Thousands of Properties

One illustrative example is a prototype of a compact combustion chamber. Its inner surface, exposed to high-temperature gases, is made of heat-resistant bronze. The outer shell uses a nickel-based alloy, while a gradient transition layer between them ensures efficient heat dissipation. This architecture resolves several conflicting engineering requirements at once: it withstands extreme temperatures, maintains structural integrity, and prevents overheating. Another example is a gear with a functionally graded structure, where a wear-resistant surface is combined with a damping core, extending service life while reducing noise and vibration.

Speed is another critical advantage. The entire process, including post-processing, takes only a few days. Conventional manufacturing – milling, welding, assembly – typically requires months. For Russian industry, this is not just a time saving. It opens the door to a new design philosophy. Engineers can now move beyond selecting materials and instead “program” how material properties are distributed inside a single component.

Russia stands on the threshold of a large-scale industrial transformation, where additive technologies are becoming one of the key growth drivers. 3D printing erases the boundary between design and manufacturing, significantly shortens time-to-market, and opens new opportunities to strengthen technological sovereignty and industrial independence

Ruslan Akhmedov

Head of a Department at the Machine Tool Building and Heavy Engineering Directorate, Ministry of Industry and Trade of Russia

The application potential is broad. In aerospace and rocket engineering, the technology targets hot engine sections where low weight, thermal stability, and mechanical strength are essential. In mechanical engineering, it enables friction units with significantly extended service life. In medicine, it supports implants that combine a biocompatible titanium surface with an elastic or damping core made from cobalt-chromium alloys. In equipment maintenance, it enables localized restoration of worn areas without replacing entire parts, sharply reducing operating costs.

If Russian developers succeed in achieving repeatable serial production and standardized processes, the technology could evolve into an export niche – not for machines, but for engineering expertise, technological protocols, and joint R&D projects.

Nuclear Power, Space, and 3D Printing

By 2030, the global additive manufacturing market could exceed $110 billion, and Russia is steadily securing its position within it. As early as 2023, the Russian market reached 12 billion rubles (approximately $145 million), seven years ahead of earlier forecasts. Domestic manufacturers now account for more than 54% of the market, with annual growth estimated at 20%.

The government is actively supporting the sector through the Strategy for the Development of Additive Technologies Through 2030, national projects, and the creation of 180 additive manufacturing centers. More than 150 additive manufacturing companies are currently operating in Russia, with around 60 specializing specifically in metal 3D printing.

Metal additive manufacturing has emerged as the leading segment, showcasing the strength of the national ecosystem. Major state corporations – Rosatom, Rostec, Roscosmos, and VIAM – are acting as primary drivers of development.

From Priority-2030 to Global Leadership

Today, Russia’s additive manufacturing sector is no longer about import substitution alone. It has evolved into a full-fledged technological ecosystem positioned to compete globally.

The SPbPU development aligns closely with the goals of the Priority-2030 program and reinforces Russia’s standing within the global Industry 4.0 landscape. Multi-material additive manufacturing is widely regarded as one of the most promising directions worldwide. Similar challenges are being addressed, for example, at Germany’s Fraunhofer IGCV Institute, where engineers are developing components with embedded sensors and hybrid metal-ceramic structures. What sets the St. Petersburg team apart is its elegant solution to the interface problem – the critical bottleneck that researchers around the world continue to struggle with.

In the coming years, pilot production runs are expected for engine manufacturing and power engineering. Over the medium term, the technology is expected to transition to small-batch production. Key challenges include quality control of gradient zones and the economics of post-processing – issues that remain central to both global and Russian research agendas. Still, the direction is clear: the future belongs to components without boundaries.