Researchers from Ocean University of China have developed a scalable method for producing lab-grown fish fillets using edible porous microcarriers (EPMs) and bioprinting.With growing concerns over overfishing, climate change, and food security, cultivated seafood has been gaining attention as an alternative to traditional aquaculture. But scaling up production while keeping the texture, structure, and nutritional profile intact remains a challenge. Now, a study published in Nature Communications details how fish muscle and fat cells can be efficiently expanded, structured into a bioink, and 3D printed into fillets that closely mimic wild-caught seafood.a) Properties of microcarrier-based cellular microtissues bioinks. The diagram was created using BioRender. b) The appearance of raw and cooked 3D printed cultured fish fillet prototypes. Image via Ocean University of China.Porous microcarriers enable high-density cell expansionAs per the team, this research focused on optimizing gelatin-based EPMs to improve cell adhesion, growth, and differentiation. By introducing sodium chloride (NaCl) during cryogenic crosslinking, scientists controlled ice crystal formation to fine-tune pore size, creating a scaffold with the right porosity for high-density cell culture.With this method, muscle satellite cells (SCs) and adipose-derived stem cells (ASCs) from large yellow croakers expanded to densities of 6.25 105 and 5.77 105 cells/mL marking a 499-fold and 461-fold increase, respectively.To test scalability, the researchers moved from 125-milliliter spinner flasks to a 4-liter bioreactor, where consecutive expansion cycles kept cell viability above 80%. The collagenase digestion method proved the most effective for transferring cells onto fresh microcarriers, maintaining uniform distribution and preventing cell loss.RNA sequencing confirmed that these expanded cells retained their ability to differentiate, with notable increases in genes related to muscle growth, extracellular matrix remodeling, and cell cycle regulation.Once matured, muscle and fat microtissues were mixed into a bioink, which was extruded through a commercial 3D bioprinter to create structured fish fillets measuring 100 mm in length and 15 mm in height. The printed fillets had layered textures similar to natural fish muscle and developed a browned surface after cooking due to the Maillard reaction.Analysis showed that the printed fish fillets retained moisture (~70%) and had a weight loss of ~35%, similar to conventional fish. However, textural properties like chewiness and cohesiveness were slightly lower, leaving room for refinement in food structuring.Nutritionally, the cultured fish had 8.5 grams more protein per 100 grams than its natural counterpart, with 68.92% less fat and an 87.93% reduction in cholesterol. The omega-3 fatty acid profile remained stable, though sodium content was higher, exceeding that of natural fish by 192.7 mg/100 g. A 51% increase in essential amino acids was also observed, while flavor compound analysis highlighted differences in volatile organic profiles, suggesting areas for further optimization in taste and aroma.Although scaling up remains a challenge, researchers estimate that a 100-liter bioreactor could yield around 750 grams of cultured fish per batch, signaling commercial potential for EPM-based cell expansion.While this study demonstrates significant progress in structured cultivated seafood, fine-tuning fiber alignment, bioink composition, and production costs will be key to making lab-grown fish market-ready.This research highlights the feasibility of scalable cultivated fish production, positioning bioprinting and high-density cell culture as tools that could reshape the future of seafood. As technology advances, lab-grown fish may soon offer a sustainable alternative to meet global demand while reducing pressure on marine ecosystems.3D printing fishes on the riseEfforts to improve alternative seafood are expanding, with companies exploring unique approaches. Last year, Vienna-based food-tech company Revo Foods teamed up with Belgian-based Paleo to make its 3D printed vegan salmon even more realistic.Revo Foods 3D printed salmon filet. Photo via Revo Foods. Backed by a 2.2M grant from the EUs Eureka Eurostars program, the two-year project, which began in August 2024, will see Paleo developing a specially fermented Myoglobin protein to enhance the taste, texture, and nutritional value of Revo Foods salmon alternative. Typically found in animal muscle, Myoglobin will be recreated without animal use to add color, iron, and aroma. Adding to this development, Revo Foods claimed its 3D printing process cuts water use by 90% and CO2 emissions by 75%.Back in 2020, Legendary Vish, a startup founded by a group of international students, was working to bring 3D printed plant-based fish alternatives to market. The idea stemmed from a 2017 EU-funded research project, where the team developed an extrusion-based method to create structured salmon fillets using plant-based bio-inks.Their goal was to offer a sustainable seafood alternative amid growing concerns over overfishing and environmental damage. As they sought investment to scale production, they also explored regulatory approval and potential partnerships to expand into Scandinavian and European markets.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows a) Properties of microcarrier-based cellular microtissues bioinks. The diagram was created using BioRender. b) The appearance of raw and cooked 3D printed cultured fish fillet prototypes. Image via Ocean University of China.

US-based 3D printer manufacturer 3D Systems has introduced its latest developments in dental 3D printing at LMT Lab Day 2025 at the Hyatt Regency Chicago.Taking place from February 20 22, this launch includes the new NextDent 300 MultiJet 3D printer designed to simplify denture manufacturing by allowing fully cured, multi-material dentures to be printed directly, removing the need for additional post-curing steps.By streamlining this process, the company aims to help dental labs work more efficiently while improving the production of patient-specific dentures. Alongside the new printer, 3D Systems is preparing to introduce solutions for night guards and direct-printed aligners, signaling its continued investment in digital dentistry.Attendees at the event will have an opportunity to see these new developments in action at Booth A-43/B-42 in the East Exhibit Hall. The company will also host seminars in the Comiskey Room, West Tower, Bronze Level, providing further insights into its latest advancements. Moreover, pre-orders for the NextDent Jetted Denture Solution will be available at the show, with general availability planned for Q3 2025.Dr. Jeffrey Graves, President & CEO, 3D Systems, said, Our decades of experience developing specialized dental materials and 3D printing technology along with our deep applications expertise will allow us to bring a full spectrum of high-volume production solutions to market in the coming years. Were committed to this expansion and are working closely with key players in every dental product category to accelerate the availability of these advancements.This news followed right after the companys Co-Founder and CTO, Chuck Hull was elected to the National Academy of Engineering. He said, Im honored and excited to serve and work alongside such outstanding professionals to advance the positive impact engineering has on our world.The NextDent 300 is part of 3D Systems FDA-cleared complete workflow solution that enables high-volume dental laboratories to rapidly produce dentures. Image via 3D Systems.Expanding multi-material 3D printing in dental careAccording to the manufacturer, the NextDent 300 introduces a multi-material printing approach that enables dental professionals to produce monolithic dentures more efficiently.Complementing this system, 3D Systems has developed two new materials: NextDent Jet Teeth, designed to replicate the durability and appearance of natural teeth, and NextDent Jet Base, formulated to provide impact resistance. Both materials are integrated into an FDA-cleared workflow that combines hardware, software, and printing technology to ensure high-quality production standards.For dental labs handling high volumes of dentures, efficiency plays a key role in meeting patient needs. Building on this need, the new system can print up to 15 arches in approximately nine hours, helping to reduce production times and allowing prosthodontists to deliver finished dentures more quickly.Beyond dentures, 3D Systems is working on expanding the same multi-material printing technology to night guards, a type of dental appliance commonly used to protect teeth from grinding or to aid in sleep apnea treatment. With increasing awareness of these conditions and demand for customized solutions, the company expects night guards to become a key addition to its dental portfolio by late 2025.In the orthodontics sector, the company is also developing a direct-printing solution for clear aligners. As a key supplier of 3D printing technology to the aligner industry, 3D Systems says it currently contributes to the production of roughly one million patient-specific aligners daily. The introduction of direct-printing capabilities is expected to enhance production speed and efficiency, with availability anticipated in 2026.According to Vantage Market Research cited by 3D Systems, the global dental 3D printing market is projected to reach $14.6 billion by 2032. With a portfolio that includes more than 30 applications, 3D Systems aims to keep contributing novel solutions to the industry.Last year, the US-based manufacturer introduced a multi-material 3D printed denture solution, marking what it claimed to be the first jetted, monolithic denture offering in the industry. This solution was later seen receiving an FDA approval in October.Unlike traditional solutions that use a single material, this system features distinct materials for gums and teeth, NextDent Jet Denture Base for impact absorption and NextDent Jet Denture Teeth for enhanced aesthetics and rigidity. Aimed at high-volume production, the technology promises faster turnaround times with improved durability.3D Systems unique multi-material, single-piece dentures offer an unparalleled combination of distinctive break resistance and outstanding aesthetics. Image via 3D Systems.Technical specifications of NextDent 300 MultiJet 3D printerInterested customers can visit the company at the show, or its website to learn more about the pricing details.Printable area (X x Y x Z)294 x 211 x 50 mm (11.6 x 8.3 x 2.0 in)Resolution800 x 900 x 800 DPILayer Thickness32 mControl Panel7 HD display with multi-touch screenDimensions (W x D x H)1183 x 740 x 1077 mm (47 x 29 x 42 in)Weight247 kg (546 lbs)Electrical100-127 VAC, 50/60 Hz, single-phase,15AA 200-240 VAC, 50 Hz, single-phase, 10AOperating Humidity30-70% relative humidityNoise< 65 dBa estimated (at medium fan setting)Software3D Sprint for preparing and monitoring printsWhat3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

The United States Patent and Trademark Office (USPTO) has granted Nikes patent for a new footwear 3D printing process.In the global fashion brands novel method, digital designs are 3D printed onto fabric material to create the shoes upper. The sole is then 3D printed directly onto this section, eliminating the need for traditional two-part shoe construction techniques.Nikes approach offers advanced material customization, allowing designers to enhance strength, rigidity, support, flexibility, and abrasion resistance. Removing heavy adhesives, stitching, and excess material layers could also enable lighter footwear designs. Additionally, the newly granted patent (US-12226973-B2) has the potential to reduce material waste, making custom products more sustainable.David P. Jones and Ryan R. Larson are the key investors named in the patent, which was first filed in December 2023 and published last April before being granted this week. Jones is a co-inventor on several patents related to 3D printing directly onto fabric for apparel assembly. Larson, Director of Nikes Digital & 3D Cushioning Systems for Footwear Cushioning Innovations, is also an active figure in the companys additive manufacturing efforts.A diagram showing Nikes new patented footwear 3D printing process. Image via the United States Patent and Trademark Office.Over a decade of 3D printed footwear innovation at NikeAdditive manufacturing is nothing new at Nike. Back in 2013, the Oregon-based shoe-making giant unveiled its first 3D printed football boot, the Vapor Laser Talon. SLS additive manufacturing was used to produce the cleats footplate, reportedly cutting the weight to 158 grams for faster sprinting and optimal traction.Several announcements followed, including a 2016 partnership to leverage HPs Multi Jet Fusion (MJF) 3D printing technology. That same year, Nike introduced Zoom Superfly Flyknit running shoes, designed for 7-time Olympic gold medal-winning sprinter Allyson Felix. Spike plate prototypes were 3D printed in SLS to determine the perfect ratio of flexibility to bounce. This reportedly reduced iteration times to days, accelerating the design process. Legendary Jamaican Womens 100m sprinter Shelly-Ann Fraser-Pryce also collaborated with Nike to prototype custom 3D printed footwear for the 2016 Olympic Games.The world-leading shoemaker continued its 3D printing-enabled athlete collaborations in 2018, when former mens marathon world-record holder Eliud Kipchoge adopted Nike shoes with a fully 3D printed upper section.The Vaporfly Elite Flyprint shoes marked a distinct move away from the companys use of additive manufacturing, shifting from prototyping to production. At the time, Nikes senior director for global running footwear, Bret Schoolmeester, told Wired, This is the first [3D printed] upper that will be more mass applicable. Later that year, Nike extended the release of these athlete-grade running shoes into the wider market.More recently, Nike made headlines last year with the launch of Air Max 1000, its first sneaker produced almost entirely with 3D printing. Unveiled at ComplexCon in Las Vegas, the new design was developed with Berlin-based Zellerfeld, a company known for its 3D printed footwear expertise. 1,000 pairs were made available through a raffle preorder at the Vegas-based fashion and music event.A side view of the 3D printed Nike Air Max 1000. Photo via Nike.Nikes new footwear 3D printing patentContinuing Nikes additive manufacturing efforts, the companys newly patented approach could be used to fabricate 3D printed shoes in the future.According to the official document, digital 3D patterns are first created for the shoes upper and sole sections. Next, a piece of knitted, woven, or nonwoven fabric is placed flat on a tray inside a 3D printer. An ink, resin, acrylic, polymer, or thermoplastic-based material is extruded directly onto the fabric to create the desired pattern.According to the patent, the extruded material may be slightly absorbed into the fabric before curing. Additionally, multiple layers can be 3D printed to create reinforced zones where needed, unlocking added strength and flexibility. Once printed, the pattern is cured with UV light. This step is vital to creating a strong blend between the fabric and extruded material. The flat upper section is then formed into a 3D shape, conforming to the final shoe design.3D printing the upper in Nikes newly patented footwear 3D printing process. Image via the United States Patent and Trademark Office.Next, the upper section is placed upside down inside the 3D printer. Using at least one pre-determined three-dimensional grip pattern, the sole is 3D printed directly onto the upper. The patent highlights that midsole and outsole layers can be made from flexible, cushioned materials like polyurethane or foam rubber, enhancing comfort and durability. Additionally, an optional sock liner can be added to the upper for a more secure fit. The sole section is also UV-cured to harden the material. Finally, the completed shoe undergoes quality control checks.The patent indicates that this process applies to a variety of sports footwear, including shoes for athletics, basketball, soccer, cycling, tennis, baseball, cross-training, and hiking. It also highlights that the method can be applied to create other types of footwear, such as dress shoes, loafers, sandals, slippers, boat shoes, and work boots.Additionally, the document reveals that Nikes new 3D printing process isnt limited to footwear. It can also be used to manufacture a range of clothing, apparel, and equipment, such as hats, jackets, shirts, gloves, and other sports gear made from fabric, leather, rubber, and foam.This draws parallels with other technologies in the garment 3D printing space. Israel-based 3D printer manufacturer Stratasys, for instance, offers the J850 TechStyle fashion 3D printer. This system features direct-to-textile technology that can 3D print designs and patterns directly onto clothing such as jeans and jackets. The 3D printer is compatible with denim, cotton, polyester, and linen fabrics, allowing designers and fashion brands to personalize wearable products and meet customer style preferences. According to Stratasys, its fashion printing process minimizes material waste by converting old outfits into new, bespoke fashion products.The sole-3D printing process. Image via the United States Patent and Trademark Office.3D printed shoes: a growing industry trend3D printed shoes are a growing trend in the additive manufacturing and footwear industries. Increasing interest is driven by the technologys ability to create unique and personalized designs to meet customer needs with minimal material usage.Nike isnt the only footwear brand to embrace additive manufacturing. Earlier this year, the luxury Italian fashion brand Gucci expanded its Spring Summer 2025 (SS25) collection by introducing several new designs of its 3D printed Cub3d sneakers. Initially released last year in a limited run of just 20 pairs, the sneakers are now available in five color options: Purple, Grey, Black, Brown, and Grey-and-white.These 3D printed shoes combine Demetra and mesh in their upper construction. Gucci developed the Demetra material, at least 70% of which is composed of vegetable-derived raw ingredients like viscose, wood pulp, and bio-based polyurethane. The bi-material sole features an EVA-filled cushioning interior and a TPU exterior for added flexibility.Elsewhere, Florida-based footwear developer Syntilay recently introduced new 3D printed sliders designed using artificial intelligence (AI). Available for $150, the shoes are 3D printed to meet specific customer specifications. Buyers scan their feet with a smartphone camera to produce an accurate model for sizing. Human designers sketch the initial concepts before AI platforms like MidJourney refine these ideas into more detailed forms. AI design software Vizcom then converts the sketches into 3D models, which are fabricated in collaboration with Zellerfeld.Another company 3D printing footwear is ELASTIUM. Last year, the UAE-based startup partnered with LaLaLand Production & Design, Californias largest shoe manufacturer, to expand additive manufacturing in the footwear industry. The companies are working to accelerate localized and sustainable mass production through their No-MMOQ hybrid production model, which can reportedly cut initial investment costs by up to 80%.The first product launched under this collaboration, the Orca, Elastiums latest 3D printed sneaker. It combines a TPU foam midsole with an elastane and TPU upper. Shipping for this product commenced last November, with prices starting at $250.Who won the 2024 3D Printing Industry Awards?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows schematics of a Nike shoe. Image via the United States Patent and Trademark Office.

Angus Logue, an engineer specializing in electrooptical systems, has developed the DNV Digital Thermal Fusion Night Vision Gogglesa helmetmounted system that overlays thermal imagery onto visible-light digital night vision in real time. Claimed to be the first affordable system of its kind, this device aims to enhance situational awareness for nocturnal wildlife observation and other low-light applications. A 264192 thermal sensor works in tandem with a low-light CMOS camera, while an integrated infrared spotlight supplements image capture. Early technical documentation emphasizes that this approach is not merely an incremental update but a fundamental shift in combining heat signatures with detailed visual information.DNV Digital Thermal Fusion Night Vision Goggles. Photo via Angus Logue.A key element in this project is the use of 3D printing to accelerate development and iterate design improvements. Rapid prototyping via FDM 3D printing allowed Logues to fabricate custom components for the helmet mounting and housing of the optical assembly. Such additive manufacturing techniques enabled precise integration of internal processing components with robust, waterproof enclosures. Molded silicone gaskets and other off-the-shelf assemblies ensured that prototypes could withstand harsh environmental conditions, a requirement for reliable field use.Assembly and wiring process of the DNV Digital Thermal Fusion Night Vision Goggles, featuring 3D printed components and integrated electronics. Photo via Angus Logue.Central to the devices performance is its reliance on an embedded computing platform built around a Raspberry Pi, a single-board computer renowned for its versatility in prototyping and low-power applications. Engineers optimized firmware to run efficiently on this platform, allowing real-time image fusion without imposing significant processing overhead. Custom camera firmware integrates digital magnification, image capture, and precise alignment of thermal and visible-light images.Rigorous testing protocols combined laboratory and field evaluations to assess performance across the infrared and thermal spectra. Iterative design cycles refined hardware integration, firmware efficiency, and ergonomic factors. Empirical data from these evaluations provided insights into trade-offs between image resolution and system portability, prompting further refinements in both sensor alignment and processing algorithms. Detailed assessments confirmed that blending thermal and digital imaging could yield a comprehensive picture in low-light environmentsa significant improvement over conventional monocular systems that often induce eye strain.Engineer Angus Logue setting up a field test for the DNV night vision system. Photo via Angus Logue.While claims of affordability remain subject to market comparisons, the DNV Digital Thermal Fusion Night Vision Goggles represent a substantial advance in cost-effective, portable imaging technology. Future development may focus on incorporating higher resolution sensors and more advanced processing capabilities to expand the devices applicability.A rendering of the DNV Digital Thermal Fusion Night Vision Goggles mounted on a helmet. Photo via Angus Logue.3D Printing for Rapid Prototyping and Modular Hardware IntegrationJames Bruton, a robotics engineer and former toy designer, developed an omni-directional ball-wheeled bike utilizing 3D printed structural components. The bikes housing and wheel support structures were fabricated using SLS 3D printing, allowing precise customization without expensive molds. Bruton employed PCB-based motor control systems to drive the wheel mechanisms, iterating on component placement and stability adjustments through rapid prototyping.Beth Le, a designer focusing on modular electronics, developed the Beth Deck, a handheld gaming device built from 3D printed components. The console integrates a Framework 13-inch laptop mainboard, a custom 3D printed housing, and an 8-inch touchscreen, enabling users to assemble or upgrade the system without soldering. The devices thermal performance required design modifications, leading to planned revisions for better airflow and reduced overheating in future iterations.Testing the omni-directional ball-wheeled bike. Image via James Bruton.Ready to discover who won the 20243D Printing Industry Awards?What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured image shows the DNV Digital Thermal Fusion Night Vision Goggles. Photo via Angus Logue.

Researchers from University of Illinois Urbana-Champaign have developed a novel method to fabricate ultra-fine fibers with diameters as small as 1.5 m, offering a scalable way to replicate biological fibrous structures.Published in Nature Communications, this study also saw contributions from University of Cambridge, Chapman University, and Hongik University researchers. Known as 3D printing by rapid solvent exchange (3DPX), the technique allows for the creation of fibers extending tens of centimeters in length, with potential applications in robotics, medicine, and advanced materials.Unlike conventional fabrication methods, which struggle with flexibility and high aspect ratios, this approach leverages solvent exchange to enable rapid solidification of extruded polymer filaments. This process reaches speeds of 5 mm/s, significantly outpacing traditional meniscus-guided printing. By allowing fibers to solidify almost instantly, capillary-induced breakage is prevented, ensuring the stability of fine structures.In nature, there are many examples of filamentous structures that achieve a diameter of only a few microns, said, Mohammad Tanver Hossain, an engineer at the University of Illinois Urbana-Champaign in a press release. We knew it had to be possible.A spiral structure produced using embedded 3D printing. Image via M. Tanver Hossain.3D printing ultra-fine fibersExperiments showed that 1.5 m fibers could be produced using a 5 m nozzle, with aspect ratios exceeding 3,400. The researchers fine-tuned the support gel rheology and polymer composition to ensure stability, proving that even at this scale, the process remains reliable.The technique also works across a broad range of materials, including thermoplastic elastomers, polystyrene, and polyvinyl chloride (PVC). They even tested carbon nanotube-polymer nanocomposites, which could be useful for applications in electronics and sensor technology.Beyond individual fibers, the team successfully printed hair-like arrays anchored onto elastomeric substrates, with diameters under 2 m and lengths surpassing 1,500 m. These could prove valuable in tactile sensors, microneedles for drug delivery, and microfluidic devices, taking inspiration from natures own solutions for sensing and adhesion.Scalability was another key focus. A multi-nozzle printing system demonstrated the ability to fabricate multiple structures at once, with a nine-nozzle manifold producing identical prints in parallel. This capability enhances industrial applications, where efficiency and precision are equally important.The team also experimented with coils, spirals, and curved filaments, showing that the printing speed and the gels yield stress have a direct impact on how well a filament holds its shape. At higher yield stress values, the gel provided better mechanical support, preventing filaments from shifting during extrusion. Slower printing speeds allowed for more controlled deposition, ensuring that fibers adhered closely to the intended trajectory.Compared to existing methods, 3DPX sets a new record for feature size in direct ink writing. Previous embedded 3D printing techniques, such as those using curable silicone elastomers, struggled to get below 8 m, while this approach cuts that down to 1.5 m. Unlike electrohydrodynamic (EHD) printing and aerosol jet printing, which tend to be slow and require external supports, 3DPX works faster and allows for freeform, unsupported printing.As with any research, this study also faced its distinct challenges. Handling ultra-high-aspect-ratio fibers after printing remains tricky, and further refinements in material formulations and support gel properties could help improve stability.According to Hossain, this method holds strong potential, as ultra-fine and long fibers could be combined with functional materials to enable replication of nature-inspired fibrous structures.Broader advances in micro-3D printingAway from University of Illinois, other researchers have also tackled challenges in micro-3D printing, exploring different methods to enhance precision and efficiency.Last year, Israeli 3D printer manufacturer Nano Dimension 3D printed a micro-scale medical device to record neuronal activity in mice for a biomedical research project. Partnering with Qubecs CERVO Research Center, Universit Laval, and Bordeaux University, and Institut des Maladies Neurodgnratives (IMN) researchers, the company used its Fabrica Micro 3D printer to achieve the micron-level precision needed for the 2.7 mm-wide brace.Printed using bio-compatible Fabrica Medical M-810 material, the device features 110m-sized holes for electrodes and was fabricated in just one week, significantly reducing the production time from several months. The brace ensured stable electrode placement despite animal movements, allowing researchers to overcome previous limitations in studying dorsal horn neurons in awake mice.Elsewhere, Stanford University researchers developed a high-speed roll-to-roll CLIP (r2rCLIP) 3D printing process capable of producing up to one million microscale particles per day. By integrating continuous liquid interface production (CLIP) with a modular film system, the team replaced the static build plate with a PET film assembly line, automating printing, washing, curing, and removal.This fully automated system enables high-resolution, high-throughput micro-3D printing, with applications in drug delivery, microrobotics, and advanced materials. The research, led by Joseph DeSimones lab, was published in Nature, showcasing its potential for scalable 3D printing of complex microscopic structures.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows a spiral structure produced using embedded 3D printing. Image via M. Tanver Hossain.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

A team of Europe-based researchers has developed a novel holographic 3D Printing method. The group created a modified Tomographic Volumetric Additive Manufacturing (TVAM) technique capable of shortening 3D printing times to mere seconds while increasing efficiency.Unlike conventional layer-by-layer 3D printing methods, TVAM can create entire objects in one shot by shining light patterns into liquid resin, which solidifies when the light intensity is high enough. While this approach can fabricate support-free, micro-scale parts within tens of seconds, it is highly inefficient. This is because under 1% of the encoded light reaches the resin vial. Conventional TVAM can also lead to unwanted distortions and poor resolution due to light blurring and projection artifacts.To address these limitations, the researchers developed HoloVAM, a new technique that uses a 3D hologram instead of conventional volumetric light projections. This approach reportedly boosts light efficiency by 20 times, resulting in faster and more accurate 3D printing. According to their paper, published in Nature Communications, HoloVAM successfully fabricated several millimeter-scale objects in under 60 seconds with fine details as small as 31 micrometers.The scientists behind the discovery are based between the Laboratory of Applied Photonic Devices at Switzerlands EPFL and the University of Southern Denmarks Centre for Photonics Engineering. They believe this new approach offers value for medical bioprinting applications, thanks to HoloVAMs use of self-healing beams. These can generate and retain their shape when passing through materials, which is particularly valuable when 3D printing with cell-laden bio-resins and hydrogels.The researchers holographic 3D printing technology. Image via Nature Communications.Holographic 3D printing enhances speed and efficiency A key challenge in existing TVAM approaches is efficiency. Most light is lost, wasting energy and reducing 3D printing accuracy. To tackle this, the researchers used a hologram tiling technique called HoloTile. Invented by University of Southern Denmark professor Jesper Glckstad, this approach breaks the 3D hologram of the desired part into smaller tiled sections. It works by projecting multiple detailed holograms into the resin, which solidifies where the light is most intense.A key challenge in holographic projections is speckle-noise, unwanted patterns caused by laser light interference. To eliminate this, the HoloTile system rapidly displays holographic patterns up to 22,000 per second. Additionally, the laser beams phase is adjusted to break up noise patterns, while specialized Bessel and vortex beams provide more stable light distribution. Unlike traditional 3D printing, which constructs objects layer by layer, HoloTile leverages a rotating resin veil. This continuous motion shifts the speckle pattern, naturally blurring out noise and resulting in smooth edges and fine details.The researchers tested their novel method using a commercial polyacrylate resin and a hydrogel with embedded cells to 3D print a range of high-resolution objects. These included 3D Benchy models, microscopic pillars, and lattice structures.Small details like the Benchys sharp bow, hollow cabin, and chimney were well preserved. One Benchy test even showcased a 28.6 times increase in light efficiency, compared to conventional methods. Additional test prints, including a cylinder with a hole, a Bucky Ball, and a Poporo artifact, were printed in 37.03 seconds and 29.88 seconds, respectively. They exhibited impressive quality and surface finish, confirming the holographic methods versatility.The technique was also successfully applied to hydrogels containing living cells. The researchers found that using Bessel and Vortex self-healing beams improved 3D print quality and penetration depth in these soft, scattering materials. Additionally, unlike conventional methods, no digital correction of projection patterns was needed, highlighting its value for biomedical applications.3D Benchy fabricated using holographic 3D printing. Photo via Nature Communications.Research unlocks 3D bioprinting breakthroughs3D bioprinting is a key focus among academics, with many institutions working to optimize this valuable process. Indeed, the HoloVAM team is not the only group pursuing volumetric printing for biomedical applications.Scientists at UMC Utrecht previously made several key innovations in this field. These include creating biologically functional regions in 3D printed cells, optimizing bioprinted cells with granular gels, and 3D printing blood vessels using volumetric bioprinting and melt electrowriting. The team hopes these breakthroughs will pave the way for expanded clinical use of 3D bioprinting.Elsewhere, researchers from Collins BioMicrosystems Laboratory at the University of Melbourne introduced a new 3D bioprinting approach called Dynamic Interface Printing (DIP). Unlike layer-by-layer approaches, DIP uses acoustic waves to guide cells into precise configurations, allowing complex, 3D printed human tissues to be fabricated in seconds. This reportedly offers the potential for customized, high-fidelity tissue structures that offer value across regenerative medicine and disease modeling applications.Who won the 2024 3D Printing Industry Awards?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows a 3D Benchy fabricated using holographic 3D printing. Photo via Nature Communications.

Swedish manufacturing technology company Hexagon has extended its long-term partnership with the Oracle Red Bull Racing F1 Team.The new multi-season deal builds on an 18-year-long relationship in which Hexagon, the teams exclusive metrology partner, has supplied Red Bull with 3D scanners and digitalization capabilities. This technology reportedly allows the F1 racing stalwart, which powers reigning F1 champion Max Verstappen, to make over 20,000 car design changes each season.The Stockholm-based firm claims that its metrology technology helped Red Bull Racing reduce faults by over 50% over the past two years. Hexagons ultra-fast scanning technologies reportedly ensure that every F1 car component meets required accuracy standards, helping the team comply with FIA regulations and spending caps.As part of the renewal agreement, Hexagons logo will appear on the lower sidepod of the RB21, Red Bulls car for the 2025 season. Branding will also appear across Oracle Red Bull Sim Racing liveries at the F1 Sim Racing World Championship and Porsche Esports Supercup.Hexagon has played a vital role in the success weve achieved over a long period as a valued partner to the team, commented Christian Horner, Oracle Red Bull Racings Team Principal and CEO. Our technology partners are a crucial element for us and were very selective about who we work with. Hexagon will ensure our competitiveness for years to come.Close-up of Oracle Red Bull Racings new RB21 F1 car, featuring the Hexagon logo. Image via HexagonHexagon extends partnership with Red Bull F1 teamAdditive manufacturing is integral to Red Bulls F1 success. Ian Handscombe, Head of Quality Engineering at Red Bull Racing, previously told 3D Printing Industry, I dont think we will continue to be on track unless we embrace [3D printing].Technical partnerships with companies like Hexagon play a vital role in supporting additive manufacturing at Red Bull Racing, and its efforts to edge out the competition. We couldnt do it without the expert support we get from our partners, added Handscombe. The leading F1 engineer called Hexagon instrumental in determining what equipment is needed, supporting delivery, assisting in development, and providing training. Hexagon has been with us every step of the way, he added.Hexagon claims that the accuracy offered by its 3D scanning and measurement technology unlocks extreme precision and quality at the first attempt for unmatched productivity. The Swedish firm believes its capabilities and trackside support will be pivotal in refining aerodynamics and unlocking precision during the 2025 campaign.Next year, the 2026 F1 season will introduce new competition regulations, including increased battery power, 100% sustainable fuels, updated wings, and stronger structures for improved safety. As such, all cars will need to be completely redesigned. Hexagon claims that its digitization technology will allow Red Bull Racing to push the limits of these new requirements to extract maximum performance.At Hexagon, were honored to continue our partnership with Oracle Red Bull Racing, where our advanced measurement technologies play a key role in driving on-track success, commented Josh Weiss, Hexagons Manufacturing Intelligence division president. Sharing a legacy of entrepreneurial spirit, innovation, and excellence, were excited to face the challenges of the upcoming season and embrace an even greener, more exhilarating era in 2026 and beyond.The new renewal agreement will also see Hexagon expand its partnership with Oracle Red Bull Sim Racing, the Milton Keynes-based teams virtual racing division. According to Hexagon, this new collaboration seeks to inspire the next generation of STEM professionals, bridging the gap between digital and physical racing.Crew poses for a photo during Red Bull Racing 2023 Pitch Black Pit Stop in Milton Keynes, England. Photo via Magenta Stills / Red Bull Content.3D printing bolsters F1 performance Beyond Red Bull, many F1 teams actively leverage additive manufacturing to support the design, testing, and production stages of car development. Global automotive firm Ford Motor Company is using the technology as it prepares for its first F1 race in two decades during the 2026 season.Through this initiative, Ford is working with Red Bull Powertrains, the engineering arm behind Red Bull Racings F1 power units. Over 1,000 3D printed car parts have already been fabricated at Fords additive manufacturing labs. These include cold plates for batteries and cooling plates for other systems, which will feed into the vehicles internal combustion engine and hybrid technology.Fords additive manufacturing team also measures mechanical strength, hardness, and precise geometry through 3D scanning. Non-destructive X-ray and CT scanning is then used to generate digital 3D models and reveal internal structures that would remain hidden with conventional inspection tools.Another F1 team using 3D printing is BWT Alpine F1. The Estonian outfit previously purchased four SLA 750 3D printers from Rock Hill-based additive manufacturing company 3D Systems. The racing team leverages this technology to fabricate components for wind tunnel testing, using SLA and SLS 3D printers to produce 25,000 parts annually. BWT Alpines 3D Systems technology, which processes Accura Composite PIV material, reportedly reduces preparation time and optimizes testing performance.Who won the 2024 3D Printing Industry Awards?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows a close-up of Oracle Red Bull Racings new F1 car, featuring the Hexagon logo. Image via Hexagon.

Texas-based construction 3D printing company ICON has secured $56 million in Series C funding, following a layoff announcement last month.Co-led by Norwest Venture Partners and Tiger Global Management, this funding round marked the first close with an additional $75 million in funding expected. Existing investors, including CAZ Investments, LENX, Modern Ventures, Oakhouse Partners, and Overmatch Ventures, also participated. Having previously invested in the company, Will Hurd, a former Congressman and Presidential candidate, has joined ICONs board of directors. While ICON has not disclosed its current valuation or whether it has changed since previous rounds, the company has now raised more than $500 million in total funding according to TechCrunch.A large portion of the new capital is being allocated toward Phoenix, ICONs line of multi-story 3D printers, with plans to make the technology available to builders. The company has also developed a new low-carbon building material designed for use in multi-story construction.Even as it moves toward equipping builders with its technology, the Texas-based firm isnt stepping away from direct construction. The company still plans to take on select projects across residential, hospitality, and affordable housing, as well as work with the U.S. Department of Defense (DoD).Interior aspects of ICONs 3D printed homes. Photo via ICON.ICONs construction 3D printing effortsOver the years, ICON reportedly held funding rounds to advance its construction 3D printing efforts. Back in 2022, the construction company raised $185 million, extending its $207 million Series B funding round from the previous year.Led by Tiger Global, this funding came from existing backers and pushed ICONs total funding to $461 million, with its valuation reportedly nearing $2 billion. While ICON didnt comment on the raise, its previous funding rounds focused on scaling operations, growing its team, and advancing research and development (R&D) in construction 3D printing.In 2018, the company pulled in its first funding round valuing $9 million to construct sustainable 3D printed houses around the world. One of the recent ICONs housing projects include eight single-family homes in Wimberley Springs, 40 miles south of Austin, Texas.Designed using ICONs AlphaBeta and TexNext collections, these homes range from 2,800 to 4,000 sq. ft. with four to five bedrooms. Built with high thermal performance concrete and low-carbon materials, they meet EnergyStar standards and offer enhanced energy efficiency. Equipped with smart thermostats, video doorbells, and durable 3D printed walls, these homes are available for pre-sale, starting in the upper $800,000s.In December 2022, ICON landed a $57.2 million NASA contract under Phase III of the SBIR program to push forward Project Olympus, a plan to build lunar structures using 3D printing and lunar regolith. The project involved testing the system in space and studying lunar materials to fine-tune construction methods. As part of NASAs Artemis Program, the goal was to lay the groundwork for a sustainable human presence on the Moon.NASAs Vulcan 3D printer installed at the NASA Johnson Space Center. Photo via ICON.Investment in construction continuesAs the potential of construction 3D printing is being realized, many companies have started investing in the technology. Last year, Amazons Climate Pledge Fund joined Holcim and British International Investment (BII) in a Series A-1 investment round for 14Trees, a company focused on 3D printing for construction.Although the amount remains unknown, the investment is said to support the deployment of advanced 3D printers, software, and sustainable materials to develop low-carbon data centers, large-scale buildings, and utilities across Europe and the U.S.Two years ago, Mighty Buildings raised $52 million in funding to accelerate its expansion into fastest-growing construction markets, Saudi Arabia and the UAE. In addition, the company also sought to scale U.S. production to meet rising demand for sustainable housing.This round was co-led by Waed Ventures, backed by Saudi Aramco, and BOLD Capital Partners, with nearly 20 investors, including Khosla Ventures and South Koreas KB-Badgers, participating.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows lawn area of ICONs 3D printed homes. Photo via ICON.

A legal battle is underway within the 3D printed firearms community. Last year, Florida-based firearm attorney Matthew Larosiere filed a lawsuit against Cody Wilson, best known for his association with the Liberator, one of the first widely available 3D printed gun files.Larosiere accuses Wilson of stealing his copyrighted gun designs and selling them without permission on the file-sharing site DEFCAD. The case was filed in the U.S District Court Middle District of Florida Orlando Division. According to the defendants and experts consulted for this article, the case could have wide-ranging implications for open-source 3D printing.Wilson has hit back against the lawsuit. He claims that the arguments of his gun-designing rival are unfounded because digital files of functional objects, including firearms, are not protected by copyright. The 37-year-old gun rights activist told 3D Printing Industry that Larosiere has resorted to copyright without principle out of basic pride, avarice, and a will to influence the culture of 3D gun printing.Open-source advocate Michael Weinberg shared his insights on this case. The OSHWA board member echoed Wilsons claims that firearms cannot be copyrighted and explained why the lawsuit could establish a precedent that shapes the future of 3D printing.However, Larosiere maintains that his files, registered with the U.S. Copyright Office (USCO), are protected and cannot be considered functional in the digital realm. The plaintiff accuses Wilson of stealing his designs for profit and falsely associating him with a massively problematic individual. Dismissing concerns that the lawsuit could have broader implications for open-source, Larosiere called the case an existential threat to Wilsons business model of charging money for other peoples work.Larosiere is seeking damages for lost revenue, reputational harm, and legal costs. A partner at Zermay Law Group and former Director of Legal Policy at the Firearms Policy Coalition, he has called for a court order to stop Wilson from redistributing the files.I also spoke with Dr. Yannick Veilleux-Lepage, an Assistant Professor at the Royal Military College of Canada whose research spans terrorism, political violence, and criminal use of emerging technologies. He believes this dispute reflects broader divisions within the 3D printed firearms space, which faces ideological tensions and personality clashes. According to the global terrorism expert, this highlights inherent contradictions within a community that thrives on decentralization and open-source collaboration.James Madison Memorial building of the US Library of Congress, which houses the US Copyright Office. Photo via Architecture of Congress.Matthew Larosiere sues Cody Wilson for copyright infringement Larosieres copyright infringement lawsuit names Wilson as a defendant alongside DEFCAD and Defense Distributed (Wilsons open-source digital firearms organization). Dioskouri LLC is also targeted. According to the official court document, this entity is run by Wilson and operates PrecursorParts.com, a website that reportedly handles online payments for USB drives containing gun files.In the lawsuit, Wilson is accused of uploading several copyrighted files, images, and text documents registered with the USCO to DEFCAD without permission. These include the Plastikov V4, BUBAR, SF5, KF5, MPP99, Hitchhiker, and Amigo Grande, 3D gun designs owned by Larosiere.DEFCAD is accessible through a $60-per-year-subscription. Wilson and Defense Distributed also allegedly sell USB drives containing digital files. Larosiere believes the defendants are re-posting his work solely for financial gain. Its certainly just to make money, he told me. Its not fair for somebody to make money from my hard work, especially in this clear and brash way.The pro-gun attorney is also concerned that Wilsons actions are damaging his reputation, causing him personal and professional harm. He claims that DEFCAD falsely implies that the copyrighted works were uploaded with permission and that the uploader allows unrestricted rights to create and distribute derivative works.Additionally, Larosiere claims that DEFCAD has created fake accounts falsely purporting to be 3D gun designers, including himself (under his online handle Fudd Busters) and John Elik (also known as Ivan The Troll). Elik designed the infamous FGC-9 3D printed gun and contributed to some of the copyrighted models in this case.Any files he [Wilson] gets, he makes a profile for that person and forces the association, the plaintiff stated. Larosiere asserted that he never agreed to his designs being used in this way. I did not upload any of these things, but they have made their website look like I have, and they even put my logo on it, he added. I dont want people to think Im affiliated with this guy.Larosiere believes Wilson has created fake profiles to avail himself of Section 230 protections. Part of the Communications Decency Act, Section 203 protects online platforms from liability for content published by third-party users. The firearms lawyer told me that Wilson misunderstands section 230, because the protection falls away when theyre not the ones uploading it.Wilson responded to these allegations, stating, Like most things in this case, Larosiere misunderstands what hes looking at. The University of Central Arkansas graduate explained that his file-sharing platform includes an encyclopedic function. As such, DEFCAD keeps multiple points of metadata about a file, including its original creator. Wilson noted that while Elik happened to create his own profile on the site, it would be accurate to assign his files to his profile even if he didnt.Inside the U.S. Copyright Office. Photo via the U.S. Copyright Office.Can 3D printed guns be copyrighted?Wilson stated that the only allegations he is concerned with are whether the USCO can register the 3D design files of useful objects like firearms or their components. This is a claim that the defendants vehemently dispute, meaning the lawsuit would fail at the first hurdle. Out of the gate, its tempting to ask ourselves questions like: Are 3D models copyrightable? But that isnt the right inquiry, Wilson told me. Instead, Wilson highlighted the U.S. Copyright Act, which denotes only works as copyrightable.Pointing to the lawsuit, Wilson claims that Larosiere is under the mistaken impression that 3D models or CAD files are a distinct or separate category of protectable work. The Forbes 30 Under 30 alumni added, If you ask him [Larosiere], hell say hes only registered 3D design models. But thats not even how American copyright works. You can only register creative works, of which 3D models are merely considered copies.Wilson emphasized that copyright legislation only protects creative works and does not cover functional devices. He highlighted Section 101 of the Copyright Act, which explicitly excludes protection for designs of useful articles, explained Wilson. The law defines such articles as having an intrinsic utilitarian function that is not merely to portray the appearance of the article or to convey information.According to the defendant, In our case, the works are not creative 3D sculptures, or 3D visual artworks, as Larosiere suggests. Instead, he noted, the files in question cover functional firearm parts like assemblies and receivers. The decisions behind their creation are functional. Each component is meant to assemble into a functioning open bolt .22 firearm.Weinberg added that firearms themselves cannot be protected by copyright because Copyright does not protect functional, useful objects. While patents can be used to protect functional models, none of the disputed files feature any patent protection. Larosiere should have pursued design patents, added Wilson. However, since most of his work is notoriously given away to the public for free, he cant.Weinberg highlighted that the Copyright Office registered Larosieres designs as models and not functional objects. He believes this registration has unclear implications for those who want to use them as functional objects. However, Weinberg calls it bad policy to extend copyright protection to CAD files for purely functional objects like firearms. This is because it could become a back door way to expand copyright protection to functional objects.Ultimately, Wilson is confident in defeating Larosieres suit. I dont think Larosiere is experienced enough in IP matters, or litigation, to prevail, the gun designer declared. His decision to bring a lawsuit was intended more to influence the current community of designers in the 3D gun space than to create good law. While a victory for Larosiere in the district court would require an appeal to overturn, Wilson emphasized that he is ready to go the distance.Cody Wilson. Photo via Cody Wilson.Larosiere defends copyright claims Despite Wilsons arguments, Larosiere remains confident that his designs are copyright-protected. The Floridian gun lawyer argues that the Copyright Act safeguards all works of the visual arts, including 2D and 3D models and technical drawings. He explained, A useful article has to be a physical object, meaning the firearm designs and models are protectable since they exist in the digital realm.He argues that the defendants belief is a misunderstanding based on the Star Athletica v. Varsity Brands case. This copyright protection dispute arose when Varsity Brands, a major cheerleading uniform manufacturer, sued Star Athletica for copying its uniform designs. The Supreme Court sided with Varsity, ruling that if a design can exist separately from the functional object, it can be copyrighted.Wilson and his co-defendants cite this ruling in their response, arguing it validates their claims that 3D printable gun files are not copyrightable. However, according to Larosiere, this presupposes that his registered designs are useful articles. The Floridian gun lawyer argues that the Copyright Act safeguards all works of the visual arts, including 2D and 3D models and technical drawings. The plaintiffs official reply to Wilsons response points to Tecnoglass, LLC v. RC Home Showcase, Inc., a case which found the statutory definition of useful articleexcludes technical drawings.Larosiere stressed that a copyrighted drawing or modelsuch as those Wilson allegedly stole and republishedshould not be mistaken for the physical object it represents. If models and technical drawings have the same protection as the thing they depict, it would mean that you could not copyright a technical drawing or a model, he noted. So why would the Copyright Acts specifically list technical drawings and models in both two and three dimensions?The Plaintiff also told me that his lawsuit is not concerned with challenging the ability of individuals to 3D print gun files, even those protected by copyright. Instead, Larosiere is solely focused on preventing Wilson from selling the copyrighted models. Nowhere do we ever say you cannot make a physical thing, he explained. Its always stop selling my drawing.In their response to the lawsuit, the defendants agreed to remove the allegedly infringing images and text for the duration of the case. They reportedly made this decision because claims about 3D models are the most important part of both the overall action and this motion. However, they maintain that claims about 2D photos and text are completely meritless and plan to seek a final judgment dismissing them. According to Wilson and his co-defendants, this makes the arguments against these files moot in the current lawsuit. Larosiere, however, argued that this move amounts to an admission that Wilson stole the copyrighted photographs and written works, and claimed that some remain online. He still has like three of them up. We brought it to their attention, and they didnt take them down, Larosiere said. Among the remaining files is allegedly a word-for-word reproduction of the Hitchhiker gun design. Wilson denies these accusations. He told me that Larosiere has hidden five miniature pieces of text/images in the designs to work as a kind of DRM. Wilson claimed that these pieces of ancillary expressive material serve as Lockout Codes. The Defendant argues that these are hidden in the files to help an otherwise invalid copyright claim survive a courts severability analysis. However, Wilson avowed, Its not going to work here. The Zermay Law Group attorney also criticized Wilsons Black Flag White Paper, a critique of Larosiere and copyright law. The document frames the enforcement of intellectual property as antithetical to the libertarian and buccaneering origins of 3D printed firearms. Larosiere, however, calls it an aggressive misunderstanding of copyright, wherein he admits to removing the copyright notices from my models.Matthew Larosiere. Photo via Matthew Larosiere.Division in the 3D printed gun communityLarosiere and Wilsons legal dispute highlights growing tensions within the 3D printed firearms community. Veilleux-Lepage describes an interesting paradox among supporters of 3D printed guns. On one hand, the community is seen as a broad church, uniting people with diverse ideologies under the shared goal of advancing privately made firearms. In contrast, geographic and ideological divisions have surfaced, fueling very public feuds and personality clashes between key figures.Veilleux-Lepage notes that many members advocate for an open-source spirit to refine designs, improve manufacturing techniques, and push the limits of what is possible with 3D-printed firearms. This level of freedom reflects the core libertarian and anti-establishment ethos which underpins many 3D printed gun designs. In a previous conversation, Veilleux-Lepage noted that, in some circles, the act of choosing a 3D printed firearm is driven by ideology as opposed to necessity. Homemade weapons are symbols of defiance against state control, he explained, unlocking unrestricted access to firearms around the world.However, the community is not homogeneous, leading to significant underlying conflicts. A geographical divide exists around the American-centric focus on part-kit completion kits, which combine 3D printed and conventional firearm parts inaccessible outside the US. According to Veilleux-Lepage, designers and makers in other countries argue that this approach limits the global applicability of many firearm projects. He also highlighted a fundamental ideological divide between those who advocate for fully open-access build guides and STL files and those who aim to monetize their designs.Although Wilson charges money for gun files, he stressed that free access is foundational to the 3D printed gun movement. He called the license for the Liberator an immanent critique of the use of copyright in open hardware licenses. Wilson added that there is an open secret about open hardware projects: Most dont have enforceable licenses because most are outside the scope of copyright in the first place.However, the clash of personalities is arguably an even bigger point of contention in the community, often resulting in public feuds. Veilleux-Lepage identified the clear animosity between Cody Wilson of Defense Distributed and members of The Gatalog, a forum of like-minded gun designers that includes Larosiere. This animosity is particularly true of Elik, who accused Wilson and DEFCAD on X of [stealing] as much of other peoples work as they could deliberately betraying one of the promises they made to the community from the very beginning.According to Veilleux-Lepage, an interesting side-effect of these disputes is that it has removed the traditional anonymity of many in the 3D printed gun community. He explained that the researchers now have greater visibility into a movement that has traditionally been highly secretive and hostile toward journalists and academics. He added that litigation within the community is exposing key figures, shedding light on individuals who were previously known only by their pseudonyms.One notable example is Peter Celentano (pseudonym Freeman1337). In an attempt to protect his identity, Celentano allegedly provided a bogus address to the attorney handling the Everytown for Gun Safety lawsuit, which targeted manufacturers, sellers, and online distributors of firearms. He was later arrested for possessing 59 AR-style receivers which all had a third pin hole, making them legally classified as machine guns.His arrest and connection to Freeman1337 were first reported by DDLegio, a platform run by Cody Wilsons Defense Distributed. Veilleux-Lepage believes legal battles and law enforcement actions like this are inadvertently revealing the identities and activities of individuals who had, until now, remained deeply anonymous.Dr. Yannick Veilleux-Lepage. Photo via Dr. Yannick Veilleux-Lepage.The future of open-source 3D printingHow will Larosiere and Wilsons legal feud impact the future of open-source 3D printing? Weinberg believes the ruling could set a significant precedent for how 3D printable files are accessed online. Particularly, if the court rules that 3D gun models are copyrightable, companies throughout the 3D printing ecosystem could move to license more designs.The open-source advocate views Larosieres lawsuit as an interesting case for anyone who cares about copyright and 3D printing. He added that the outcome has the potential to clarify rules around how copyright interacts with 3D models of functional objects generally, something that could have a much larger impact.Wilson believes the outcome could affect the boundaries of 3DP and copyright. Because the case requires the exploration of the boundaries of copyright and patent law, he believes the ruling will be precedential for many more territorial disputes in the wider design and 3D printing worlds.On the other hand, Larosiere argued that a ruling in his favor would not impact the copyright sphere because its all very settled law. He added, Its hard to find comparable cases because its very rare that people so brazenly violate copyright. The plaintiff asserted that his victory would not restrict the ability of others to 3D print parts. Copyright wont prevent you from doing a 3D print, because thats the manufacture of a physical thing, he added. Whats at issue here is selling the work.Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows the U.S District Court Middle District of Florida Orlando Division HQ. Photo via the U.S District Court Middle District of Florida

Rosotics, a former U.S. developer of metal 3D printers, has announced that its Halo system, a large-format metal 3D printer, will cease commercial sales and be consolidated internally to support the production of its orbital transfer vehicles. With this transition, the company seeks to evolve from solely manufacturing launch vehicle hardware to becoming a fully complete operator in autonomous space infrastructure, said Christian LaRosa, Founder and CEO, Rosotics.Every great name in additive manufacturing that exists today became a great name because of what they used it to do. We dont plan to ignore the potential we see here, and that will demand a lot of hard choices to realize. The scope of what we intend to do in orbit will require us to be led and operated under a sole focus, and that is as a space company we plan to win the race to industrializing space, said LaRosa.Backed by Silicon Valley venture capitalist Tim Draper and recognized by Venture Capital Fund Sequoia Capital and Venture Capital Firm Andreessen Horowitz (a16z), Rosotics has secured US$2.6 million in funding to advance large-scale metal 3D printing. The Halo platform has drawn attention from companies like Relativity Space and RTX, as well as Jim Cantrell, who was part of SpaceX and served as Elon Musks early mentor.Key Features of the Halo SystemHalo is a large-format metal 3D printer, dubbed the worlds first supercreator. This term was coined by the company to highlight its ability to directly interface with materials science through adaptive code. Halo is not a 3D printer in the traditional sense; it goes beyond being just a tool. It redefines the concept of 3D printing. This system has the ability to control metallurgical science through a deep understanding of materials, representing a significant leap in the evolution of creation technology, said LaRosa.A key feature of the Halo system is its multi-phase electromagnetic process, which replaces traditional laser-based techniques. This process is driven by a print head assembly called Mjolnir, named after Thors hammer. Each Halo unit is equipped with three Mjolnir heads, mounted on freestanding towers supported by multi-axis gimbals. The company explained that the platforms control system, HalOs, incorporates industrial intelligence to monitor and adjust the deposition process, ensuring stability and precision during operation.Rosotics Restructuring and Future Aerospace InitiativesCEO LaRosa announced the departure of Co-Founder and COO Austin Thurman, alongside the companys decision to relocate its headquarters from Mesa, AZ, to Cape Canaveral, FL. In this new phase, Rosotics is actively recruiting talent to support the growing demands of vehicle production and spaceflight operations. The company also intends to streamline its maritime sector operations through strategic partnerships, shifting its focus toward space exploration.Rosotics announced it plans to deploy multiple autonomous spacecraft that will execute a maneuver around the Moon before entering orbit at the L5 Lagrange point, a stable gravitational position between the Earth and the Moon. These spacecraft, featuring large 3D-printed, unpressurized hulls, will transport smaller vehicles to L5 and later be repurposed to aid in the construction of an orbital station. Initially functioning as a propellant depot, the station will expand over time to include power generation and materials processing capabilities, all while remaining at the L5 point without the need for fuel to maintain its position.3D Printing for Space ApplicationsAlthough Laser Powder Bed Fusion (LPBF) are the most widely used metal additive manufacturing systems, other 3D printing technologies are also used for specific applications. Kansas City-based startup Raven Space Systems is focusing on addressing the demands of aerospace, space, and defense applications with its proprietary Microwave Assisted Deposition (MAD) 3D Printing technology. The company claims that its patented process enables scalable direct ink-write (DIW) 3D printing of aerospace-grade thermoset and preceramic composite components.According to Raven Space Systems, MAD technology holds promise for the production of hypersonics, propulsion vehicles, reentry vehicles, satellites, aircraft, missiles, and space rockets.Elsewhere, satellite telecommunications company AscendArc has secured US$3.95 million in pre-seed and seed funding to further develop its satellite communications technology. This announcement follows AscendArcs recent partnership with OPTISYS, an industrial engineering company focused on developing a 4.5-meter dish with a high-performance horn antenna. The collaboration integrates 3D printed radio frequency (RF) components from OPTISYS, combining precision engineering and advanced manufacturing techniques to enhance satellite signal performance.What 3D printing trends should you watch out for in 2025?How is the future of 3D printing shaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.

IperionX Limited, a U.S.-based materials company, has secured a US$47.1 million contract from the U.S. Department of Defense (DoD). This funding is aimed at fortifying the U.S. Defense industrial base by advancing the development of a reliable, cost-effective, and fully integrated titanium supply chainfrom mineral extraction to metal productionthereby enhancing national security and economic resilience.The agreement represents a combined investment of US$70.7 million, which will fund a two-phase development program over the next two years. In the first phase, the DoD has allocated US$5 million through the Industrial Base Analysis and Sustainment (IBAS) program, with IperionX contributing an additional US$1 million. These funds will expedite the Titan Critical Minerals Project in Tennessee, advancing it to project-ready statusan essential step in establishing a new domestic source of titanium, rare earths, and zircon critical minerals. The remaining US$42.1 million will be allocated to IperionXs Titanium Manufacturing Campus in Virginia, ensuring vertical integration and scaling titanium production capacity.This award is a pivotal moment in IperionXs mission to re-shore the U.S. titanium industry. For too long, American industry has been reliant on foreign-controlled supply chains for this critical high-strength metal. IperionXs proprietary technologies, combined with the Titan Project, offer a pathway for a resilient end-to-end U.S. titanium supply chain. We are proud to be selected by the DoD as a key partner in strengthening U.S. industrial and defense capabilities, said Anastasios (Taso) Arima, CEO, IperionX.The news follows a broader national security trend seeking to secure critical material supply chains, ensuring the resilience of U.S. manufacturing.Why is Titanium critical for the US Defense Industry?Titanium is crucial to the U.S. defense industry for its strength, high temperature, and corrosion resistance. It is twice as strong as aluminum and is used in aerospace, naval defense, armored vehicles, and advanced technologies. In aerospace, titaniums strength-to-weight ratio is critical for military aircraft, including fighter jets and bombers, and for parts exposed to high temperatures. In naval defense, its corrosion resistance makes it ideal for submarines and ships. Furthermore, the silver metal is crucial in missile and rocket systems, as well as in developing next-generation military technologies such as experimental aircraft.Currently, much of the worlds titanium comes from the top three producers: China, Japan, and Russia. To address this challenge, in 2024, the DoD issued a competitive solicitation to bolster the resilience of the titanium supply chain. IperionXs Hydrogen-Assisted Metallothermic Reduction (HAMR) and Hydrogen Sintering and Phase Transformation (HSPT) technologies, which offer cost-effective and high-performance alternatives for titanium production, were selected for funding.Strengthening Supply Chains: Security and Economic ResilienceSecuring national supply chains has become a prominent focus of renewed interest in industrial sovereignty. With this in mind, a number of initiatives are underway.U.S. enterprise, 6K Additive was awarded a $23.4 million DoD grant to bring waste material back into the supply chain. Our countrys national security relies heavily on materials used across numerous applications, and controlling the supply chain from within the borders of the United States is paramount, commented Frank Roberts, President of 6K Additive. No other organization has the history, experience, infrastructure or potential 6K Additive has in upcycling materials like titanium, nickel superalloys and refractory metals, added Roberts.More efficient material production is another approach. In the UK, Metalysis is developing an alternative to the Kroll process. The company talks of a revolution in metallurgy not seen since the Bronze Age, in relation to its development of the Fray, Farthing, and Chen (FFC) Cambridge electrolysis method. Instead of using titanium sponge, the FFC method can use oxides, specifically titanium dioxide.What are the 3D printing trends to watch in 2025?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter, you can also follow us on LinkedIn.While youre here, why not subscribe to our Youtube channel? Featuring discussion,debriefs, video shorts, and webinar replays.Featured image shows IperionXs Titanium Manufacturing Campus in Virginia. Photo via IperionX.

Software company nTop has acquired German firm cloudfluid, a specialist in computational fluid dynamics (CFD) simulations.With this move, the software company aims to simplify how engineers analyze fluid behavior, addressing one of CFDs long-standing challenges, lengthy simulation times that slow down design iterations. As a result, the acquisition integrates cloudfluids GPU-native solver into nTops computational design platform, providing engineers with faster, more efficient CFD analysis.On another note, nTop has also announced plans to host its second annual Computational Design Summit in Los Angeles this June.We are hyper-focused on building software that helps engineers go from requirements to design as fast as the latest computing processors allowthats the power of computational design, said Brad Rothenberg, CEO of nTop.nTop software on display at RAPID + TCT 2024. Photo via nTop on LinkedIn.Enhancing CFD simulations with faster processingAnyone whos worked with CFD knows that running a simulation can be a slow, complicated process.Traditional CFD software relies on CPU-based solvers, which process simulations sequentially, often leading to long wait times, especially when dealing with complex aerodynamic or thermal analyses. Cloudfluids GPU-native solver runs calculations in parallel, significantly speeding up simulations and making fluid dynamics analysis more practical for rapid design workflows.Another key advantage is that cloudfluid removes the need for complex meshing. Standard CFD tools require engineers to manually create detailed conformal meshes, a process that is both time-consuming and difficult to refine.Cloudfluids solver eliminates that step while maintaining accuracy, allowing engineers to focus on testing and optimizing their designs rather than spending hours preparing simulations.By integrating cloudfluids fast CFD solver with nTops implicit geometry kernel, engineers working in aerospace, defense, and turbomachinery can now test and refine designs faster. The ability to analyze fluid dynamics in near real-time makes it easier to explore different configurations, fine-tune propulsion systems, and improve thermal management, all without slowing down development cycles.Beyond performance improvements, this integration also supports machine learning applications in engineering.High-quality simulation data is essential for predictive modeling in digital twins and design optimization, yet generating reliable datasets has traditionally been costly and time-intensive. Cloudfluids capabilities enable engineers to produce these datasets more efficiently, making AI-driven decision-making more accessible for manufacturers and designers.This acquisition follows previous collaborations in the high-performance computing space. Prior to this, nTop collaborated with GPU manufacturer Nvidia to integrate its computational design software with OptiX ray tracing and Omniverse, bringing faster visualization and simulation capabilities to engineering workflows.Backed by an investment from NVentures, Nvidias venture capital arm, this alliance is expected to help engineering teams iterate designs more efficiently and reduce product development timelines. Integrating Nvidias GPU-accelerated rendering technology allows nTop 5 users to generate highly detailed renderings and interact with live digital twins without the need for meshing.Engine part simulation in nTop 5. Image via nTop.Expanding engineering software capabilitiesSimilar advancements have emerged in the design software landscape, with various companies developing tools to enhance engineering workflows.Last year, Cognitive Design Systems (CDS) launched Cognitive Design, a software platform designed to help engineers optimize designs while ensuring manufacturability. According to the company, traditional CAD workflows often require switching between multiple tools, leading to time-consuming iterations and increased chances of errors.To tackle these challenges, Cognitive Design combines optimization and manufacturability into one platform, allowing engineers to refine complex geometries, reduce weight, and make real-time adjustments using simulation-driven parametric design and topological optimization. The software also includes manufacturing analysis tools to catch potential flaws early, ensuring designs can be efficiently produced.Elsewhere, engineering software developer Hyperganic launched Hyperganic Core 3, the latest version of its AI-driven algorithmic design software in 2022. Backed by a $7.8 million funding round, the platform allows engineers to design 3D printable parts using algorithmic models, offering an alternative to traditional component design.Additionally, the software enables streamlined workflows in industries like aerospace, enabling complex geometries to be generated in minutes while maintaining performance optimization.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows nTop software on display at RAPID + TCT 2024. Photo via nTop on LinkedIn.

Researchers from the University of Washington (UW) have introduced a new way to 3D print mycelium-based biocomposites, sidestepping the need for traditional molds. Led by Danli Luo, alongside Junchao Yang, and Nadya Peek this approach uses a specialized 3D printable paste called Mycofluid, a custom-built 3D printing system named Fungibot, and an incubation process that []

In this article, the 3D Printing Industry engineering team reviews Formlabs Form 4 resin 3D printer.This is the fourth generation of the Massachussetts-based companys Form series, accelerating resin-based additive manufacturing with Blazing Fast 100 mm per hour 3D printing. High speeds are enabled by the companys Low Force Display (LFD) engine, a masked stereolithography (MSLA) approach that combines LCD and SLA technologies.The 3D printers sizeable build volume and compatibility with any 405 nm photopolymer resin support a wide range of applications for professional-grade 3D printing. Read on to discover why the Form 4 is an impressive option for prosumer and industrial users seeking high-speed, high-quality, versatile, and affordable 3D printing. Prices for the Form 4 start at just $4,499, with more information available on the Formlabs website.Formlabs Form 4 3D printer. Photos by 3D Printing Industry.Why choose Formlabs Form 4?Central to the Form 4 is its novel LFD 3D print engine, representing a significant shift from the laser and galvanometer technology found in most competing products. This approach minimizes the force applied during 3D printing to enhance part quality and dimensional accuracy.The engine utilizes an innovative backlit LED unit to project the models cross-sectional area onto the resin tank, curing the resin. It leverages 60 LEDs and collimating lenses to produce a uniform area projection of ultra-high power light at an intensity of 16mw/cm2.According to Formlabs, this technology enables quick and precise 3D printing, ensuring a level of accuracy that rivals injection molded parts. Indeed, the Form 4 is ideal for customers wanting to accelerate 3D printing operations. Average 3D print speeds of 40 mm/hour can be achieved with a 100 m layer height, while maximum speeds reach 100 mm/hour.The 3D printer also boasts a 50 m pixel size with pre-tuned anti-aliasing and a maximum lifetime of 1.9 million layers. Its 0.15% XY dimensional tolerances seek to ensure that part assemblies fit and function as expected.Reliability is another key selling point of the Form 4. This is underpinned by validated 3D printer settings, precise heating mechanisms, force-sensing, and debris-detection capabilities. As such, Formlabs claims its fourth-generation product offers an unmatched 3D print success rate exceeding 98.7%, ideal for professionals targeting high-volume production.The Formlabs Form 4. Photos by 3D Printing Industry. User-friendly hardware with a premium feel Fitting a sizeable 200 mm x 125 mm x 210 mm build volume into a desktop-sized unit, the Form 4 offers the premium, high-quality feel we expect from Formlabs. Its sturdy metal chassis, distinct orange-tinted anti-UV door, and user-friendly touch-screen user interface (UI) create a premium, minimalist profile that would fit well into most workspaces.Form 4 unboxing and assembly is a breeze. No tools are required, and we had our 3D printer up and running in just 15 minutes. 60-point calibration and quality control inspection are conducted before each 3D printer leaves the factory, guaranteeing high-quality 3D printing straight out of the box.Formlabs Form 4 unboxing and kit contents. Photos by 3D Printing Industry.Formlabs fourth-generation 3D printer features a new, specialized resin tank. This incorporates a large dual-film system that works in conjunction with the LFD technology to ensure consistent, high-quality 3D printing and easy layer peeling. Formlabs Form 4 resin tanks can process over 75,000 layers, translating to 1 to 2 years for most users.The 200 mm x 125 mm print bed is also optimized for ease of use. It can be removed with one hand, while its solid, non-perforated design simplifies cleaning. However, parts often adhere strongly to the surface, risking damage. A built-in camera captures the entire build plate, allowing users to conduct remote build monitoring and capture 3D printing time-lapses.Form 4 resin tank and build plate. Photos by 3D Printing Industry.Formlabs end-to-end 3D printing ecosystemOur engineering team also tested Formlabs Form Wash (2nd Generation) and Form Cure post-processing units, which combine with the Form 4 to create an end-to-end 3D printing ecosystem.Once a 3D printing job is completed, the part must be washed to remove any toxic uncured resin. Liquid solvents, like Isopropyl alcohol, are usually used to achieve this. We were impressed by the Form Wash, which significantly reduces the need for direct contact with washing solvents. This provides a safer and cleaner alternative to manual wash stations, where users risk inhaling harmful IPA fumes and spilling solvents.After cleaning, 3D printed parts should be cured in UV light to further harden the resin. This helps to stabilize material properties, enhance surface quality, and improve part tolerances and accuracy. The Form Washs 405 nm light, 100 W heater, turntable, and reflective interior enable thorough polymerization at temperatures up to 80. Additionally, its plug-and-play functionality and user-friendly interface ensure a seamless curing process for users of all experience levels.Formlabs Form Wash (2nd Generation) and Form Cure post-processing units. Photos by 3D Printing Industry.PreForm 3D printing softwareFormlabs Form 4 is controlled by the companys proprietary, free-to-use PreForm 3D printing software. Compatible across all Formlabs 3D printers, PreForm stands out thanks to its intuitive interface and control over essential 3D printing tasks.The software allows users to easily slice models, generate supports, manipulate parts, and modify designs. It can also be used to simultaneously manage multiple Formlabs 3D printers, ideal for 3D print farms and high-volume production environments.PreForms One-Click Print feature is particularly valuable. This automates several key processes to reliably ensure successful 3D printing. These include model repair, orientation, automatic support generation, and build area layout adjustments to prevent overlap. The file can then be uploaded directly to the Form 4, making for an incredibly straightforward and hassle-free process.For industrial users handling high production volumes, manually adjusting each part on the print bed can lead to significant delays. To address these challenges, PreForms layout function automatically arranges all models to maximize build area usage. Once a model has been loaded and oriented, the software can automatically generate and analyze support structures to enhance final part quality.While we were impressed by PreForms straightforward usability and functionality, its simplicity could be limiting for more experienced users. Features like nesting, non-uniform scaling, in-slicer model editing, and custom cutting tools are all missing, preventing more advanced 3D printing possibilities.PreForm layout, One-Click Print feature, and support generation. Images by 3D Printing Industry.Intuitive UI streamlines 3D printingThe Form 4s seven-inch touchscreen UI also stood out to our testing team. This intuitive, easy-to-navigate interface provides preventative maintenance reminders, information on 3D print status, and printer readiness, removing questions from the production process.The Form 4 makes maintenance effortless by displaying critical diagnostic tools on-screen. If an issue arises, a QR code directs users to relevant support articles for quick troubleshooting, an invaluable tool for resin 3D printing newcomers. Looking ahead, Formlabs plans to enhance accessibility further with firmware updates, including new language options.Calibration steps on the Form 4s 7-inch, touchscreen user interface. Photos by 3D Printing Industry.Benchmarking the Form 4How does the Form 4 compare to other resin 3D printers on the market? To find out, we conducted several benchmarking prints, which will also test the claims made by Formlabs.The first, a mandibular dental model commonly 3D printed during dental training, was initiated using PreForms One-click Print function. This was impressive, featuring exceptional surface quality with no visible layer lines. The auto-support generation system worked perfectly, requiring minimal manual tweaking of the 3D model before printing. Post-processing was also straightforward. All residue was cleaned off in under ten minutes, with effective curing completed in half an hour.3D printed mandibular dental model. Photos by 3D Printing Industry. The Form 4 stands out with its notable build volume of 200 mm x 125 mm x 210 mm. However, some slicers restrict users from fully utilizing the printers advertised capacity. Does this impact the Form 4? For the Z-axis, our tower test found no restrictions and our part achieved a height of 210 mm.Form 4 3D printed tower test. Photos by 3D Printing Industry.During this test, we were particularly impressed by PreForms Print Validation feature, which helps users identify potential issues before the printing process begins. For example, during the tower test, the validation system detected risks associated with printing tall parts and recommended adding vent holes to reduce the cupping effect. This feature is invaluable for users who prioritize reliability and want to avoid the frustration of failed prints.Print validation warnings. Image by 3D Printing Industry.Next, we conducted a perimeter test to assess the maximum 200 mm x 125 mm limits along the X and Y axes. When importing the STL file into PreForm, we encountered a warning stating that the model exceeded the build volume, despite it measuring the exact advertised dimensions.This occurred because the software compensates for material shrinkage during printing. To handle shrinkage, the printer applies a standard scale correction for each material. In this case, the correction was 1.0049 mm. Fortunately, this shrinkage only caused a minor reduction of less than one millimeter in the overall size, which would have a negligible impact on most applications.3D printed perimeter test. Photos by 3D Printing Industry. Parts with complex geometries often feature overhanging sections. This can pose challenges for resin 3D printers. To assess how the Form 4 deals with these challenges, we 3D printed two models with six overhangs increasing in 5 from 40 to 65.Both parts were successful, with all angles completed to a good standard. However, we did observe a faint rippling defect. This was likely caused by the peeling force during the early stages of 3D printing. Interestingly, the rippling effect disappeared approximately one-quarter of the way into the print, leaving a completely smooth overhang at angles up to 65. This minor anomaly did not impact the integrity of the print, with the test confirming the Form 4s ability to handle overhang geometries.3D printer overhang tests. Photos by 3D Printing Industry. Many users turn to resin 3D printers due to their advantages in producing parts with small dimensions and tight tolerances. To assess the Form 4s capabilities for these applications, we 3D printed a functional M8 nut and bolt with a coarse pitch size of 1.25 mm.These small parts were successfully produced with impressive detail in 1 hour. They were 3D printed on a raft to prevent an elephant foot effect, a common defect where the initial layers are flattened or widened. Once removed and post-processed, the nut and bolt fit together seamlessly, confirming the Form 4 can 3D print small and precise parts to desired tolerances.3D printed M8 X 1.25 mm nut and bolt. Photos by 3D Printing Industry. However, our next attempt to produce a nut and bolt with a 1 mm thread pitch was unsuccessful. As the threads became finer, the Form 4 failed to maintain the required resolution. As such, we can confirm that the 3D printer has limitations when fabricating ultra-fine-pitch threads, limiting its value for certain high-resolution applications.3D printed M6 X 1 mm nut and bolt print. Photos by 3D Printing Industry.To test the Form 4s ability to handle fine details, we 3D printed a small J3D Tech Definition test cube. This coin-sized model includes three surfaces with complex shapes and intricate details.The test showed that the printer can produce high-quality, ultra-detailed parts. While there were minor issues with extremely thin walls, the overall results were impressive. Therefore, the Form 4 is well-suited for making small, detailed parts with complex designs.3D printed J3D Tech Definition test cube. Photos by 3D Printing Industry.Repeatability is essential when producing batches of identical parts. To determine the Form 4s value for this application, we 3D printed a test model 12 times, each of which was measured and compared to the intended dimensions. Most proficient 3D printers will achieve an average deviation of less than 0.05 mm and a standard deviation under 0.25 mm.3D printed repeatability parts. Photos by 3D Printing Industry.All twelve test pieces were 3D printed and processed with no significant defects. The measurements ultimately highlighted the strong repeatability of the Form 4. The average deviation came to 0.0477 mm, just below the 0.05mm benchmark. While this highlighted commendable precision, these parts were negatively impacted by Z-axis deviations caused by uncured, trapped resin or support touchpoints being cured inside the hole section. The X and Y axes exhibited identical results, reflecting great consistency across all models.The standard deviation was a remarkable 0.0155 mm compared to the 0.25 mm target. This confirms Formlabs claims regarding the Form 4s reliability and precision, helping it stand out as a consistently high-quality professional-grade resin 3D printer.Repeatability differences between the measurement and reference. Image by 3D Printing Industry.Testing Form 4 3D printing applicationsEngineers and manufacturers often leverage resin 3D printers to fabricate functional, end-use parts. Formlabs offers a range of resins optimized for these parts, featuring mechanical properties for a range of applications.The companys Grey V5 resin is well known for its versatility and robust mechanical properties. To assess the ability of the Form 4 to produce functional parts with this material, we fabricated motorcycle fuel pump hose clips. This component attaches to the fuel hose to the pump, preventing any accidental dislodgement. The original equipment manufacturer of this particular component no longer produces these clips, meaning resin 3D printing offers an excellent alternative to producing aftermarket parts.We 3D printed a batch of 24 fuel pump clips, with a total print time of 7 hours. The Form 4 performed exceptionally well here, with all components produced with intricate features perfectly preserved. The surface text was rendered perfectly, rivaling the quality of its injection-molded counterparts.3D printed fuel pump clips. Photos by 3D Printing Industry. Another popular application of desktop resin 3D printers is the production of figurines and miniature models with fine details. To assess whether the Form 4 is a good choice for enthusiasts and designers targeting the arts and crafts market, we produced a Viking figurine with a 25 m layer thickness.The 3D printer again performed exceptionally well here, delivering an impressive surface finish with consistent layer buildup and no anomalies. Post-processing was straightforward, with the model washed, dried, and cured with minimal manual input. Some issues were encountered with support removal. Even after reducing the touchpoints to a size of 0.35 mm, we were unable to achieve clean breaks, with many supports generated in delicate areas of the model. Despite this, we were thoroughly impressed with the Form 4s performance.3D printed Viking model. Photos by 3D Printing Industry. Next, we used the translucent Clear V5 material to 3D print a breathing mouthpiece that connects two snorkeling components. We sought to produce an end-use part that was strong, damage-resistant, and highly precise. Clear V5 achieved this with flying colors.The part had an impressive transparent effect, free from the cloudiness often seen in other translucent resins. It also showed no yellowing, which is a common issue with similar clear materials. The high clarity and smooth surface finish eliminated the need for extra post-processing, like polishing or smoothing, and support removal left minimal marks.3D printed breathing tube mouthpiece. Photos by 3D Printing Industry. The use of additive manufacturing is growing within the medical sector, as on-site 3D printers significantly reduce lead times and support patient-specific customization. To assess the Form 4s value for the production of medical devices, we 3D printed a primary oxygen splitter assembly. Clear V5 resin was again used to enable easy inspection of the splitters internal channels. Additionally, the material is not reactive to oxygen, a critical factor for this oxygen-heavy part.Despite 3D printing all parts, the Form 4 encountered a critical issue that rendered the final product unusable. The 3D printer could not achieve the required precision for the threaded connections. Attempts to join these sections resulted in the threads grinding against each other, preventing proper assembly. To correct this, the parts would need to be re-designed with a coarser thread pitch.3D printed oxygen splitter assembly. Photos by 3D Printing Industry.Resin 3D printers are also witnessing increased adoption within the eyewear sector, offering benefits for sustainability, personalization, and localized production. Is the Form 4 well suited to serve this growing market? We were pleased with the quality of our 3D printed sunglasses frames, which were produced with the finest layer height of 25m.However, support removal again caused issues, leaving small dents and marks on the frame. Moreover, after a few uses the threaded connector sections failed, largely due to the brittle nature of Formlabs Clear V5 resin. Therefore, a more flexible 3D printable resin would likely achieve better results for the functional frame.3D printed sunglasses frame. Photos by 3D Printing Industry.Elastic 50a, a silicone-like material, offers much better flexibility and durability. To assess the Form 4s ability to 3D print more stretchable components we 3D printed a soft robotic gripper prototype. Pumping air or water into its channels causes the gripper to contract, allowing it to grip small objects.The quality of this prototype was excellent, with perfect channels and good functionality. Post-processing was greatly successful, although the surface remained slightly sticky after washing and curing. Users should note that Elastic 50A is fragile and prone to tearing when removed from the build platform, an issue we experienced twice during our testing. To avoid this, we recommend using Formlabs new Flex Platform, an upgraded version designed to facilitate easier part removal.3D printed robotic gripper. Photos by 3D printing Industry.The Form 4: high-speed, professional-grade 3D printingThe Formlabs Form 4 is a reliable, high-performance resin 3D printer that combines impressive accuracy and versatility with affordability and ease of use. The efficiency and reliability provided by Formlabs LFD technology make the Form 4 ideal for professional and industrial-scale users seeking an adept production system at a low price point.Notably, the Blazing Fast 100 mm/hour maximum and 40 mm/hour average production speeds significantly accelerate the resin 3D printing process. This, in turn, reduces lead times, expands output, and saves money, increasing productivity by 3x for certain applications. Its accelerated production capabilities make the Form 4 well suited to engineers targeting quick prototyping, high-volume manufacturers, and print farms facing high demand.LFDs minimal peeling forces ensured a high success rate throughout our testing, which indicated impressive accuracy and precision for a range of sizes and geometries. We were particularly impressed with 3D printers repeatability, which stood out with an exceptional 0.0155 mm standard deviation.Formlabs Form Wash and Form Cure units also stood out as great options in the post-processing market. Their hands-free operation enhances the user experience, minimizing exposure to IPA solvent and other harmful chemicals. In our testing, we rarely encountered un-cured resin, with the Form Cure featuring tunable settings optimized for Formlabs materials.PreForm software further elevated our testing experience. Its easy-to-use interface allows users of all experience levels to reliably achieve impressive results. In particular, One-click printing significantly streamlines the production process, ensuring settings are optimized for high-quality 3D printing.Some limitations were recognized during our extensive testing. The Form 4 faces challenges with extremely fine threads, preventing functionality for screwable sections. The finer the pitch, the more likely the parts are to be affected by shrinkage, which could pose issues for certain applications. Issues were also encountered when removing support structures, which frequently damaged otherwise perfectly finished surfaces.Despite this, we were impressed with the Form 4s ability to achieve high-quality, professional-grade 3D printing at high speeds. Its affordable price makes it an incredibly competitive addition to the industrial resin 3D printer market, offering value for users requiring reliable, high-quality results in a straightforward package.Technical specification of Formlabs Form 43D Printing TechnologyLow Force Display (LFD)Build Volume200 mm x 125 mm x 210 mmLayer Thickness (Z Resolution)25 300 micronsXY Resolution50 micronsAverage 3D Printing Speed40 mm/hourMaximum 3D Printing Speed100 mm/hResin Tank Lifetime75,000+ layers with any Formlabs material3D Printer Dimensions398 x 367 x 554 mm3D Printer Weight18.3kgSoftware CompatibilityWindows 7 and up; Mac OS X 10.12 and upFile Types AcceptedSTL, OBJ, 3MFSubscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn like our Facebook page, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows the Formlabs Form 4 3D printer. Photo by 3D Printing Industry.

British engine manufacturer Rolls-Royce has partnered with the UK Ministry of Defence (MOD) to recycle fighter jet components into 3D printed engine parts.The collaboration, which features expertise from Additive Manufacturing Solutions Ltd., is converting old Royal Air Force (RAF) Tornado fighter jet parts into metal powder feedstock. This has been used to 3D print components for the Orpheus jet engine concept, which supports the Future Combat Air System (FCAS) program.Part of Rolls-Royces defense division, Orpheus seeks to accelerate engine design and production using advanced manufacturing techniques, such as 3D printing. According to Neil Mantle, the companys Director of Manufacturing, additive manufacturing previously reduced development times by 50%, with engines going from concept to testing in 18 months.Rolls-Royce believes its latest 3D printing initiative, called Tornado 2 Tempest, has the potential to support the Tempest fighter jet. Developed through Britain, Italy, and Japans Global Combat Air Programme (GCAP), the sixth-generation aircraft has already leveraged additive manufacturing. Last year, BAE Systems, the British aerospace firm leading the project, used metal 3D printing to produce primary structural components for the Tempests demonstrator. This follows BAEs 2020 statement that it planned to 3D print 30% of the Tempests parts.The Tornado 2 Tempest project exemplifies the forward-thinking sustainability principles embedded in the FCAS Sustainability Strategy and MOD Defence Support Strategy, commented Andrew Eady, Rolls-Royces VP of FCAS Sustainability.At Rolls-Royce, we continue to be leaders in circular economy practices and innovative digital enablers to support our steps to be a lower carbon and digitally enabled business, Eady added. He called Tornado 2 Tempest a bold, exciting and innovative project and a demonstration of how excellent collaboration between the MOD, industry and SME can deliver sustainable and technologically advanced solutions.RAF Tornado Fighter Jet. Photo via the RAF.3D printing recycled fighter jet partsThe Tornado fighter jet retired from RAF operations in 2019. When decommissioning, replacing, and scrapping old equipment, the MOD risks losing strategic metals. Many of its surplus assets and broken components feature valuable materials like high-quality steel, aluminum, and titanium.The Tornado 2 Tempest project aimed to explore whether surplus Tornado components could be converted into metal powder for 3D printing, creating a circular supply chain. As part of this effort, titanium Tornado partssuch as jet engine compressor blades from a low-pressure air compressorwere collected, cleaned, and atomized into metal feedstock.Rolls-Royce and AMS then used this powder to 3D print a nose cone and compressor blades, which were installed on the Orpheus test engine. After installation, the engine was tested under operational conditions to validate the safety, performance, and feasibility of 3D printed components for future military aircraft engines. The team also developed a Digital Product Passport to track material provenance and lifecycle data. According to Rolls-Royce, this could help make more informed material allocation decisions and safeguard against counterfeit materials.AMS stated it is honored to contribute its expertise in additive manufacturing to this collaborative effort, reinforcing its commitment to advancing sustainable and efficient solutions within the aerospace and defense sectors. Rob Higham, the companys Founder, added, This project turned our proposed solutions into a reality, and we have been very humbled and grateful to the MOD and Rolls-Royce, for allowing us to showcase our capability to deliver game-changing circular economy processes and parts in Defence.Rolls-Royce, AMS, and the MOD led the initiative alongside Defence Equipment and Supports (DE&S) Defence Recycling & Disposals Team (DRDT). The project was funded by the UK Strategic Commands Defence Support Organisation in support of its Circular Economics for Defence Concept Note. Over 80 people participated, including DRDTs commercial graduates and Rolls-Royce graduate apprentices.Rolls-Royces Orpheus engine. Photo via Rolls-Royce.Additive manufacturing to secure defense supply chainsShipping insecurities and geopolitical challenges are increasingly threatening global supply chains. This has led many countries, including the UK, to ramp up their sovereign military manufacturing capabilities with 3D printing. Earlier this year, armored vehicle manufacturer Rheinmetall BAE Systems Land (RBSL) announced it had attracted over 56 million in investment to accelerate defense manufacturing at its Hadley Castle Works Factory in Telford. The company, a joint venture between the UKs BAE Systems and Dsseldorf-based Rheinmetall, is leveraging additive manufacturing to produce the next-generation Challenger 3 main battle tank and Boxer armored personnel carrier on British soil.Maria Eagle, Minister for Defence Procurement, recently visited the Telford site as part of the UK Governments new Defense Industrial Strategy. This initiative seeks to ensure the countrys defense sector is innovative, resilient, and competitive. During the visit, Eagle stated that Telford is at the heart of UK defence, with the new Government strategy designed to drive economic growth, boost British jobs, and strengthen national security.A 950 million Challenger 3 contract has already created 300 jobs across RBSLs facilities in Telford, Dorset, Bristol, and Newcastle. This was followed by a 5 billion investment to equip UK forces with 148 Challenger 3 tanks and 623 Boxer vehicles by 2030.Elsewhere, the UK, Australian, and US governments agreed to accelerate hypersonic technology under a new AUKUS Hypersonic Flight Test and Experimentation (HyFliTE) Project. Initially signed in 2021, the trilateral partnership is pursuing a new level of collaboration to unlock faster development, testing, and evaluation of hypersonic vehicles to bolster their sovereign aerospace and defense capabilities. This could include long-range strike missiles launched from land, sea, or air.According to the MOD, the new project seeks to bolster battle-winning capabilities, enhance domestic security, and defend against international threats. Existing research will be incorporated into the new initiative, reportedly allowing the partners to develop at a pace that no one nation could do alone. While the role of additive manufacturing has not been disclosed, the US is investing heavily in 3D printed missiles. For instance, the Department of Defense awarded rocket engine manufacturer Ursa Major with $12.5 million to develop 3D printed solid rocket motors in the US. It has also previously funded aerospace firm Aerojet Rocketdynes efforts to 3D print a prototype hypersonic propulsion system.Who won the 2024 3D Printing Industry Awards?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows an RAF Tornado Fighter Jet. Photo via the RAF.

Researchers from the University of Twente (UT) and University of Southern Denmark (SDU) have come up with a clever way to strengthen the connection between soft and rigid materials in hybrid robots, an ongoing challenge in robotics.Interestingly, their approach turns an everyday 3D printing issue, under extrusion, into an advantage. By deliberately allowing the printer to create a porous structure, theyve found a way to improve adhesion between materials.Whats more, this method works with standard fused deposition modeling (FDM) printers, making it far more accessible than existing solutions that require expensive multi-material printers. Published in Nature, contributions came from researchers Arman Goshtasbi from SDU, Luca Grignaffini and Ali Sadeghi from UT.A bioinspired hybrid gripper mimicking a human fingernail features a rigid nail plate bonded to a porous mesh, replicating the natural bond between a nail and nail bed. Image via UT.Mimicking nature to enhance roboticsSoft and rigid components in robots each have their strengths, but getting them to bond properly has always been a tricky business. Differences in how these materials handle stress often lead to weak adhesion, with traditional bonding methods, such as adhesives, becoming failure points under mechanical strain.Nature, however, offers a solution. Just as biological connective tissues seamlessly link muscles to bones, the researchers developed a fibrous, porous structure that strengthens the connection between soft and rigid materials.This approach mirrors how tendons, ligaments, and other natural interfaces distribute stress, preventing sudden mechanical failures. Through rigorous testing, they fine-tuned the level of porosity needed to achieve an optimal balance of strength and flexibility, marking a step forward in bio-inspired robotics.The numbers tell the story. In lap shear and peel tests, this method outperformed traditional adhesives by up to 200%. Experiments with Ecoflex 00-10 and DragonSkin 10 silicone rubbers showed significantly stronger bonds compared to commonly used adhesives, giving soft robots a better shot at durability.For pneumatic soft robotics, where airtight seals are critical, the method also showed promising results. Under simulated pressure conditions, bonds created using this technique withstood forces three times greater than those joined with adhesives, reinforcing its potential for inflatable and hybrid robotic systems.By offering a simple, low-cost way to create strong bonds between different materials, this method could change how hybrid robots are made. Applications could extend to any environment where mechanical reliability is crucial, opening up new possibilities for soft robotics.According to the researchers, future work may explore ways to further refine this technique by mimicking natures gradual transitions between soft and rigid materials. Testing with alternative 3D printing materials, like ABS and PETG, could also shed light on ways to make bonds even stronger.Lap shear and peel-off test results. Image via UT.Research into bio-inspired roboticsIn the past, 3D printing has contributed to the development of several unique bio-inspired robots. One notable contribution came from researchers at the University of California San Diego, who introduced a more affordable way to 3D print soft, insect-like robots. Their flexoskeleton printing method works with standard FDM printers, layering rigid filaments onto a heated thermoplastic base.This approach simplifies production, making soft robotics more accessible by removing the need for expensive multi-material 3D printing. Drawing inspiration from insect exoskeletons, the technique balances flexibility and structural support. In tests, the printed robots demonstrated improved strength and durability, with a prototype successfully walking on its own.Elsewhere in 2022, a student from University of Surrey developed a 3D printed robotic fish designed to collect microplastics from waterways. Created by Eleanor Mackintosh in 2022, the robot, called Gillbert, featured gill-like structures with fine mesh to trap plastic particles as small as two millimeters while allowing water to pass through.The design won the 2022 Natural Robotics Contest and was successfully tested in both lab settings and a UK lake. At the time, it was remote-controlled, with future plans including to improve its swimming speed and autonomy.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows a bioinspired hybrid gripper mimicking a human fingernail features a rigid nail plate bonded to a porous mesh, replicating the natural bond between a nail and nail bed. Image via UT.

Katie Weimer, former Vice President of Regenerative Medicine 3D Systems has launched GenesisTissue Inc., a biotechnology research startup.Founded in 2024, the startup has emerged from stealth mode, specializing in surgical planning, personalized design, and the manufacturing of 3D bioprinted regenerative tissue implants for humans. While limited details are available, Weimer will serve as CEO and Co-Founder of GenesisTissue, leading a team focused on developing biomimetic materials designed to replicate natural human tissue, prioritizing regeneration over repair.Announcing the launch on LinkedIn, Weimer stated, Im grateful for the experiences and growth during my time at 3D Systems Corporation. Looking ahead, Im excited to collaborate, innovate, and shape the future of healthcare with GenesisTissue. Stay tuned!The announcement has drawn industry attention, with Rajeev Kulkarni, CSO of Axtra3D and former VP of Strategy & Corporate Development at 3D Systems, commenting on LinkedIN, Seems like an ideal time for the AM industry to embrace tissue-like solutions designed specifically for healing and restoration and keep the cutting edge moving.Katie Weimer, CEO and Co-Founder of GenesisTissue. Photo via Katie Weimer/LinkedIN.Weimers contributions to medical 3D printingWeimers began her career at Medical Modeling in 2007. After 3D Systems acquired the company, she transitioned into leadership roles, serving as Director of Product Development, later advancing to VP of Medical Devices, and ultimately VP of Regenerative Medicine.During her tenure, 3D Systems saw the launch of the Regenerative Tissue Program (RTP) in 2023, which focuses on developing bioprinted patient-specific soft tissue. She described the initiative as a significant step forward in providing personalized solutions for breast reconstruction.By leveraging 3D modeling, bioprinting, and Virtual Surgical Planning (VSP), the program aims to create bio-integrative scaffolds tailored to individual patients. Weimer also saw potential for expanding this work into applications such as lumpectomies, breast augmentation, and facial implants, highlighting the broader impact of regenerative bioprinting in medicine.One of the groundbreaking cases she worked on was the successful separation of conjoined twins, Jadon and Anias McDonald in 2016. Weimer and her team collaborated closely with surgeons, utilizing medical imaging to create detailed 3D printed models of the twins shared cranial structure.Katie Weimer and Mike Rensberger of 3D Systems hold a 3D printed surgical model used in the operation on conjoined McDonald twins. Photo via CNNThese models were instrumental in pre-surgical planning, allowing the medical team to visualize and strategize the complex procedure. Weimers direct involvement extended to being present in the operating room during the 27-hour surgery, ensuring the accurate application of the 3D printed guides and models, which were critical to the operations success.Moreover, she also contributed to SMEs 2018 report on the expanding role of medical 3D printing. At the time, point-of-care manufacturing was gaining momentum, allowing for faster, more personalized solutions in surgical planning and prosthetics.With that in mind, Weimer highlighted the industrys reliance on industrial prototyping materials and advocated for biomimetic alternatives that better replicated human anatomy. She predicted a shift toward more advanced materials, expecting the evolution of 3D printing to further enhance patient care and solidify its role in medical applications.With GenesisTissue, Weimer is entering a new phase of her career, bringing her expertise in bioprinting and regenerative medicine into a dedicated venture. Further details on the companys development and partnerships are expected as GenesisTissue moves forward.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows Katie Weimer, CEO and Co-Founder of GenesisTissue. Photo via Katie Weimer/LinkedIN.

Bambu Lab has called for Stratasys patent infringement lawsuits to be dismissed in the Eastern District of Texas, Marshall Division. However, it agrees that the case can continue to be considered in the Austin division of the Western District of Texas, where a parallel lawsuit was filed last year.The complaints, initially filed in the Eastern District in August 2024, allege that the Shenzhen-based desktop 3D printing leader infringed on ten patents owned by Stratasys, an Israeli industrial additive manufacturing OEM. The features named in the lawsuit relate to elements common to many FDM 3D printers, including purge towers, heated build platforms, tool head force detection, and networking capabilities.Stratasys allegations focus on the sale, importation, and distribution of allegedly patent-infringing 3D printers in the United States. Bambu Lab argued that the parent company is not responsible for these actions. Instead, it points to its US-based subsidiary, Bambu Lab USA, which was not named in the original lawsuit filed in the Marshall Division.The Chinese firm has filed a motion to dismiss, arguing that the case is invalid under Federal Rule of Civil Procedure 19. It contends that any party considered a primary participant in the allegations must be included as a defendant. Bambu also alleges that the Eastern District of Texas is an improper venue for the suit because Bambu Lab USA has no business operations in this jurisdiction, meaning the case should not continue there.The defendants have indicated their willingness to allow Stratasys to pursue its claims in the Western District, where Bambu Lab USA was listed as a defendant in September 2024.A Stratasys Fortus 450mc (left) and a Bambu Lab X1C (right). Image by 3D Printing industry.Stratasys vs Bambu Lab: the legal battle so farStratasys has accused Bambu Lab of patent infringements involving its X1C, X1E, P1S, P1P, A1, and A1 Mini 3D printer models. The company is seeking a jury trial to obtain an official ruling that Bambu has violated its patents. Additionally, Stratasys has requested financial compensation for the infringements, a court order preventing future violations, reimbursement for attorney fees, and other related costs.Given the widespread use of the patents in question, the lawsuit raises questions about how a pro-Stratasys ruling could impact other manufacturers.Alan Laquer, a patent litigator at Knobbe Martens, previously told 3D Printing Industry that a Stratasys victory would not automatically invalidate 3D printing patents from other OEMs who can plead their case in court. However, he noted that battle-tested patents are viewed as more powerful tools in future disputes. On the other hand, success for Bambu Lab would mean Stratasys couldnt use those patents against anyone else.Last October, Stratasys dropped charges against two named defendants in the dispute. Court documents indicated that Beijing Tiertime Technology Co., Ltd. and Beijing Yinhua Laser Rapid Prototyping and Mould Technology Co. Ltd had been removed from the case. Both defendants represent the company Tiertime, Chinas first 3D printer manufacturer. It is unclear why Tiertime was named as a defendant in the first place, with the OEM having no clear affiliation with Bambu Lab. Interestingly, both companies had previously engaged in a tit-for-tat legal battle regarding patent infringements. Stratasys sued Afinia, Tiertimes US distributor and partner, in 2013. Afinia responded in 2015 by suing uCRobotics, the Chinese distributor of MakerBot 3D printers, for allegedly infringing its 3D printing patents. Makerbot was a subsidiary of Stratasys between 2013 and 2022 when it merged with Ultimaker.The Bambu Lab X1-Carbon 3D printer. Image via Bambu Lab.Bambu Lab files motion to dismiss in Texas Marshall DivisionBambu Lab filed its motion to dismiss the lawsuit in December last year, with Stratasys responding soon after. The Israel-based company argued that as the plaintiff and Master of the Complaint, it has the right to choose which defendants to sue. It justified the decision to omit Bambu Lab USA, claiming they are not required to sue every related company and can pursue claims against just the parent company and affiliates.Stratasys alleges that Bambu Lab is seeking to rewrite the allegations in Plaintiffs Complaint to cast non-party BambuLab USA as the primary participant in the infringement. Stratasys also argued that Bambu Lab misrepresented the Federal Rule of Civil Procedure 19. The firm claimed that BambuLab USA is not a required party because its absence would neither prevent the court from granting full relief to the existing parties nor cause significant harm to the missing defendants. Stratasys maintains that it is only seeking relief from Bambu Lab, which can be held accountable without involving its US subsidiary.The plaintiff also challenges Bambu Labs dispute over the Eastern District location. It argues that venue rules cannot be used to dismiss the case and that more evidence is needed before a final decision can be made. Ultimately, the firm requested that the defendants motion be rejected and the case move forward in the Eastern District.Last month, Bambu Lab responded by repeating their arguments and countering Stratasys claims. It emphasized that its US subsidiary is a key player in 3D printer sales in North America and that their omission makes the lawsuit incomplete. The defendants claimed that the ruling could harm Bambu Lab USAs business without offering them the chance to defend themselves.This new legal document also pointed to the Fifth Circuit Court ruling in Dernick v. Bralorne Resources Ltd. and Freeman v. Northwest Acceptance Corp. According to Bambu Labs response, these cases confirm that when a subsidiary is the primary participant in the alleged wrongdoing, it must be included in the lawsuit. Bambu requested that the Eastern District case be dropped and that Stratasys be allowed to continue its lawsuit in the Western District of Texas, where all indispensable parties are named.The Stratasys booth at Formnext 2024. Photo by 3D Printing Industry.3D printing patent infringement lawsuitsPatent infringement battles are common in the additive manufacturing industry. Last year, 3D printer manufacturer Markforged settled a patent lawsuit filed by Continuous Composites. This dispute, which originated in 2021, relates to allegations that Markforged infringed on several patents held by Continuous Composites.In April 2024, a jury ruled against Markforged, ordering the Massachusetts-based company to pay $17.34 million in damages. As part of the Settlement and Patent License Agreement, Markforged agreed to pay $18 million upfront, with additional payments of $1 million in 2025, $2 million in 2026, and $4 million in 2027.Earlier this month, Spokane-based law firm Lee & Hayes PC alleged that Continuous Composites owes it more than $7 million in legal fees relating to this case. The composite 3D printing firm, on the other hand, insists its financial obligations do not exceed $3 million.Lee & Hayes stated that it was unaware of the final settlement amount until reading a Markforged press release. According to the firm, Continuous Composites acknowledged receiving $18 million but refused to pay the alleged $7.2 million owed. In response, Continuous Composites filed a counterclaim, citing an email in which Lee & Hayes had allegedly agreed to accept $3 million as a full and final payment.Elsewhere, 3D printed military drone manufacturer Firestorm Labs filed a lawsuit against its competitor RapidFlight earlier this year. In the intellectual property dispute, RapidFlight is alleged to have falsely accused San Diego-based Firestorms 3D printed Tempest drone of infringing on two patents.Filed in the United States District Court for the Southern District of California, Firestorm has requested a jury trial to confirm its innocence. The USAF-contracted drone maker argues that its competitor resorted to legal action after falling behind on technology capabilities, performance, and price. According to Firestorm, this led RapidFlight to use unsupported threats in an attempt to bully Firestorm out of the industry.Who won the 2024 3D Printing Industry Awards?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows the Bambu Lab X1-Carbon 3D printer. Image via Bambu Lab.

3DBenchy, a widely recognized 3D model used for testing and benchmarking desktop 3D printers, has been transitioned into the public domain. Originally released on April 9, 2015, by Creative Toolsa company known for its innovative digital design solutionsthis model has long served as a practical tool for assessing printer performance. In 2024, after Creative Tools was acquired by NTI, a full-service supplier of digital solutions across construction, design, manufacturing, and media & entertainment, the decision was made to open 3DBenchy to the public. Marking its 10th anniversary, NTIs move to eliminate usage restrictions reinforces the models role as a standardized tool for the 3D printing community.Daniel Nore withj a giant 3DBenchy. Photo via NTI.Daniel Nore, the original designer at Creative Tools, created 3DBenchy as a precise calibration tool for 3D printers. Under the guidance of Paulo KiefeCreative Tools CEO until 20183DBenchy was introduced under a Creative Commons: No Derivatives license. This license was intended to protect the model from modifications, ensuring consistency in performance testing. Despite these restrictions, the models design quickly became a cultural touchstone. The 3D printing community not only adopted the software as a benchmarking standard but also informally circulated various iterations, even while the licensing terms remained in place. The absence of active enforcement by Creative Tools allowed these variations to proliferate, contributing to 3DBenchys iconic status in the field.In early 2025, speculation began circulating when reports surfaced that Printables, a platform for sharing 3D designs, was removing 3DBenchy remixes. Prusa Research, the company behind Printables, later clarified a third-party report had triggered the removal, not NTI. Statements from NTI indicated no intent to restrict downloads or derivatives, but the incident underscored 3DBenchys enduring significance. Anticipation builds as the software approaches its tenth anniversary on April 9, 2025; Daniel Nore and Paulo Kiefe have assumed responsibility for managing the official website and social media channels, ensuring that the models legacy remains anchored in open access.Neon 3D Benchy boats by Javen Wilson of Mosaic Manufacturing. Photo via 3DBenchy.Advances in 3D Software and AI-Driven DesignBackflip, an AI startup founded by Greg Mark and David Benhaimveterans from industrial 3D printer manufacturer Markforgedhas introduced a new tool that converts text and image prompts into 3D models. With $30 million in funding from venture capital firms NEA and Andreessen Horowitz, Backflips platform promises to reduce the design cycle dramatically. The tools underlying technology leverages novel neural representations, which reportedly allow up to 60x more efficient training, 10x faster inference, and a spatial resolution increase of 100-fold over earlier methods.Tencent, a Chinese technology conglomerate, has also made strides in 3D software with the unveiling of Hunyuan3D 2.0. This AI-powered tool employs a dual-model approach: Hunyuan3D-DiT focuses on generating high-resolution geometry while Hunyuan3D-Paint applies realistic textures through diffusion models and geometric priors. Internal evaluations indicate that this decoupled system achieves lower Condition-Model Matching Distance (CMMD) and Frchet Inception Distance (FID) values compared to competing solutions. Hunyuan3D-Studio, a companion interface, further facilitates tasks such as sketch-to-3D conversion and simplified polygon output, thereby addressing common bottlenecks in animation and rapid prototyping workflows.An object created from 3D models generated in Backflip using text and image prompts. Photo via Backflip.Ready to discover who won the 20243D Printing Industry Awards?What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured image shows Neon 3D Benchy boats by Javen Wilson of Mosaic Manufacturing. Photo via 3DBenchy.

Netherlands-based biotechnology research company Ourobionics has launched CHIMERA, a biofabrication and biomanufacturing platform that combines five different technologies into a single system.Instead of using separate devices for different biofabrication techniques, researchers can now work with 3D Bio-ElectroSpraying, 3D Cell-ElectroSpinning, 3D Bio-ElectroJetting, 3D Melt/Cell ElectroWriting, and Standard 3D Extrusion BioPrinting all in one place. This integration is aimed at simplifying the production of complex tissues using stem cells, organoids, genes, and other biomaterials.According to the research company, CHIMERA addresses some of the main challenges in cell-based biomanufacturing by offering a modular system that enables researchers to work across different fields, including tissue engineering, regenerative medicine, and synthetic biology.CHIMERAs development was backed by a 2024 venture capital investment round led by OostNL and the 1 billion NXTGEN Hightech program. This financial support has helped position the platform as a key tool for advancing research in biomanufacturing and regenerative medicine.This CHIMERA platform is a game-changer for scientist, industrial, and medical professionals working at the forefront of tissue engineering, regenerative medicine, synthetic biology, and cell-based product biomanufacturing, said Ourobionics CTO, Dr. Ali Shooshtari.The Ourobionics CHIMERA platform. Photo via Ourobionics.Enhanced cell viability, speed, and structural precisionOne of its key capabilities is maintaining high cell viability, with up to 98% viability reported across more than 56 cell types, including stem cells and even full embryos. In terms of speed, CHIMERA significantly outpaces traditional extrusion bioprinting, producing 1cm structures in about a minute, up to 30 times faster than conventional methods.With nanoscale resolution reaching up to 50nm, the system allows for the fabrication of highly detailed scaffolding and tissue structures. It also includes encapsulation technology that can work with cells, cell clusters, genes, and gene clusters, expanding its applications in areas like cell therapies, synthetic biology, and biomanufacturing.The platform supports a wide range of biomaterials, including those with varying viscosity levels, giving researchers more flexibility in their work. By ensuring the preservation of cellular and metabolic integrity, CHIMERA addresses a common challenge in bioprinting, reducing the stress that extrusion-based techniques often place on cells.The origins of CHIMERAs bioelectro-fabrication technologies trace back to research by Prof. Suwan Jayasinghe, Founder and Chief Scientific Officer (CSO) of Ourobionics, at University College London (UCL). Additional enhancements were made by Dr. Stephen G. Gray, Founder of Ourobionics, and Dr. Shooshtari, building upon previous research from Imperial College London.As per Ourobionics, over 150 scientific publications have detailed the platforms ability to preserve cellular function while enabling the creation of complex tissue structures. Possessing a broad range of applications, CHIMERA is expected to contribute significantly to both biomedical research and industrial use cases.For researchers and companies looking for an all-in-one solution for complex tissue engineering and biomaterial development, CHIMERA aims to provide a more streamlined and efficient approach.Characteristic photographs depicting (a) control and (b) jetted embryos at the hatching period, which is 48 h post-fertilization. Jetted and control embryos are externally indistinguishable. Image via Ourobionics.Advances in biofabricationResearch into biofabrication has continued to progress, with novel studies demonstrating new approaches to creating functional tissues. In February 2024, researchers at Carnegie Mellon University (CMU) developed a 3D ice printing technique to create detailed blood vessel-like structures, offering a novel development in tissue engineering.Led by graduate student Feimo Yang alongside professors Philip LeDuc and Burak Ozdoganlar, this method involves printing ice templates using heavy water, which raises the freezing point and allows for smooth structures. These templates are embedded in a gelatin-based material that solidifies under ultra-violet (UV) light, leaving behind hollow channels once the ice melts.The process successfully supported endothelial cell growth for two weeks, indicating promise for long-term applications. Beyond organ transplantation, this approach could improve drug testing and personalized medicine by enabling patient-specific vascular models.Few months before this, scientists from the University of Sydney and the Childrens Medical Research Institute (CMRI) developed a 3D photolithographic printing method to create human tissues that closely resemble real organ structures.Led by Professors Hala Zreiqat, Patrick Tam, and Dr. Peter Newman, the research focuses on using precise mechanical and chemical signals to guide stem cells from blood and skin into specialized cells that form well-organized tissue.The team successfully produced a bone-fat assembly and replicated early mammalian development processes, demonstrating the potential of this approach. With applications in regenerative medicine, disease modeling, and cell therapy, researchers believe the technique could one day help grow functional tissues in the lab, potentially benefiting treatments for conditions like macular degeneration.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the Ourobionics CHIMERA platform. Photo via Ourobionics.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

UK-based robotics engineering startup Generative Machine is developing an open-source 5-axis fused filament fabrication (FFF) system by using Autodesks Fusion 360 software.By moving beyond the limitations of conventional 3-axis FFF 3D printers, which struggle with overhangs and complex geometries, the new system offers greater flexibility in part orientation with a tilting build platform. A multi-axis approach reduces material waste, improves surface quality, and enables the production of intricate designs that would typically require industrial equipment.According to Ric Real, PhD, Co-Founder of Generative Machine, when generative design is combined with parametric design methods, machine dimensions and performance characteristics can be dynamically adjusted, allowing new configurations to be generated instantly.Imagine just defining the required build volume, updating the parametric base configuration, and automatically regenerating an optimized machine to these new dimensions Its not difficult to see the concept of self-designing products and machines begin to emerge, and we can do it all in Fusion, he explained.Generative Machines 5-axis FFF 3D printers beta version. Photo via Autodesk.Leveraging generative design and multi-axis motion control According to Autodesk, Fusion 360s Generative Design feature played a key role in the machines structural development. The tool applies artificial intelligence (AI) and cloud computing to generate multiple design alternatives based on input parameters such as material properties, manufacturing constraints, and performance requirements.By exploring a range of possible configurations, the software refines each design for efficiency and durability. Optimizing the machines mechanical structure through this process enhances its strength-to-weight ratio while reducing unnecessary material usage.Moreover, Fusion 360 also facilitated the overall design and development of the beta version. The entire printer was modeled within the software, streamlining the iteration process.In addition to the machine itself, the UK-based startup used Autodesk Fusion to prototype metal components manufactured separately through an unspecified 3D printing method. Post-processing with CNC machining ensured these components met strict tolerances and maintained precise alignment between the printers moving axes, a critical factor in multi-axis systems where minor misalignments can significantly impact print accuracy.For motion control, the engineering startup is utilizing Duet3Ds ecosystem for motion control, enabling high-precision part production with closed-loop integration. Duet3Ds control boards, combined with RepRap firmware, provide flexibility in machine configuration, making it one of the few setups suitable for a 5-axis FFF printer.Integrating a single-board computer with the control board allows for the development of additional plugins, further expanding the platforms capabilities, highlighted Andrew Everitt, Co-Founder of Generative Machine.Fusion 360s sheet metal tools were used to design the electronics enclosure, ensuring a precise and functional housing for internal components. Custom printed circuit boards (PCBs) were also explored using Fusion Electronics, allowing Generative Machine to optimize the systems electrical architecture for a 5-axis platform.Expanding access to this technology, Generative Machine aims to make advanced 3D printing techniques more widely available to desktop users.Metal 3D printed parts post-processed using CNC machining. Image via Autodesk.Developments in 5-axis 3D printers Generative Machines 5-axis 3D printer joins the lineup of existing systems in the market. Last year, Austrian AM startup VENOX launched the V-REX, a 5-axis composite 3D printer designed for industrial and R&D applications. Having been developed since 2022 with support from Austria Wirtschaftsservice (aws) through the PreSeed DeepTech grant, the printer features a continuous fiber print head for aligning materials like carbon fibers along their natural direction, enhancing part strength.Its automatic tool changer supports up to six different print heads, enabling multi-material printing. With a print volume of 600 x 400 x 400 mm and extrusion temperatures reaching 500C, the V-REX accommodates a wide range of thermoplastics and composite materials. VENOX specializes in high-strength, multi-material 3D printing, integrating sensors, conductors, and hybrid manufacturing techniques in a single build.In 2020, Polish 3D printer manufacturer VERASHAPEs VSHAPER division introduced the VSHAPER 5AX, a 5-axis FDM 3D printer with machining capabilities aimed at engineering applications. Developed to overcome the limitations of conventional layer-by-layer printing, the system features a spinning and tilting build platform that enables multi-directional filament deposition, reinforcing part strength across multiple axes and reducing the need for support structures.The 5AX supports up to six interchangeable tool heads, including options for multi-material printing, milling, drilling, and burnishing. Originally announced in 2017, the system was developed with support from the Polish National Research and Development Center and underwent an open innovation program in 2018 to refine its design based on industry feedback.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows Generative Machines 5-axis FFF 3D printers beta version. Photo via Autodesk.

Japanese chemical company Asahi Kaseis North American subsidiary has stopped developing, marketing, and selling its 3D printing filaments.Asahi Kasei Plastics North America (APNA) entered the FDM materials market in October 2023 with the launch of filaments made from XYRON, its modified polyphenylene ether (mPPE) resin. The product line later expanded to include Thermylene, APNAs line of polypropylene (PP) compounds.However, the Michigan-based subsidiary has now exited the filament market. According to an Asahi Kasei spokesperson, this decision was made following an internal business decision.While customers will no longer be able to access APNAs line of filaments, the American business will continue to offer its Thermylene 3D printing pellet grades. These glass-reinforced materials feature high strength, stiffness, and heat resistance for automotive, aerospace, and industrial applications.Asahis spokesperson assured me that APNAs decision has not affected the companys other operations. The Japanese multinational will continue offering its Cellulose Nano Fiber (CNF)-reinforced polyamide materials for additive manufacturing.Additionally, Asahi Kasei is expanding its reach through a partnership with Italian materials manufacturer Aquafil S.p.A. Signed last October, the memorandum of understanding will see the two companies develop a new 3D printing filament for automotive and aeronautical applications.APNA headquarters in Fowlerville, MI. Photo via Asahi Kasei.Asahi Kasei Plastics North America ends filament salesAsahi Kasei decided to enter the 3D printing filament market in 2023 to capitalize on what ANPA President and Chief Operating Officer Todd Glogovsky called a rapidly growing field. During the announcement, he added that the North American business possessed the people and skillset to develop, enhance, and exceed the needs of hobbyists and OEMs alike.The plastics specialist initially presented a roadmap that promised customers a versatile and long-term commitment in the 3D printing sector. It initially sought to target sales in the North American market which would springboard a global expansion.ANPA began by trialing its XYRON filament, which offered low warpage, high dimensional stability, heat resistance, electrical insulation, and impact strength. This was followed by a Thermylene filament boasting high tensile strength, chemical resistance, creep resistance, and elevated temperature performance.During the official filament announcement, the North American business also outlined plans to advance resources through computer-aided engineering (CAE). This sought to build on the companys CAE technical services for the engineering plastics market.2023 also saw Asahi Kasei Corporate Venture Capital (CVC) invest in Israeli 3D printing software firm CASTOR Technologies Ltd. Through this move, the Japanese conglomerate is working to expand its CAE capabilities while enhancing automation and advanced simulations. There is no indication that Asahi is cutting back on its digital efforts within the additive manufacturing space.Additionally, although ANPA is exiting the 3D printing filament market, this is not the end of Asahi Kaseis FDM material sales. Through its new partnership with Aquafil, the firm is working to combine its CNF formulation with the Italian entitys ECONYL Polymer chemically recycled PA6 to create a new filament.The resulting CNF/ECONYL Polymer compound will reportedly feature high formability and strength for 3D printing applications. It has already been showcased at last years Fakuma plastics processing expo and the Formnext 2024 additive manufacturing trade show. According to Asahi Kasei, trial sales of the new 3D printing filament will begin in the EU, US, and Japan in Q3 2025.Asahi Kaseis CNF 3D printing filament. Photo via Asahi KaseiCompanies exit the 3D printing spaceBusiness exits are nothing new in the global 3D printing market. Last year, global chemical production company BASF exited the 3D printing industry after its 3D printing business, BASF Forward AM, was carved out into an independent company.Forward AMs carve-out came after the businesss leadership, led by CEO Martin Back, purchased BASFs full 3D printing portfolio. Having retained its IP and supply chain, the entity expressed its intent to meet future demand and fulfill its contractual obligations. However, following the news that insolvency proceedings had commenced towards the end of 2024, Forward AM ceased US operations last month. The firm has since partnered with RP America, a distributor and service provider, to ensure ongoing product availability and on-site support for customers in the country.Elsewhere, 2023 saw Global print and digital document corporation Xerox sell its additive manufacturing business unit, Elem Additive Solutions. This was purchased by ADDiTEC, a US-based metal 3D printer developer. Xeroxs decision to exit the AM space came amid an effort to refocus strategic priorities and investments onto its core print, IT, and digital service capabilities.Who won the 2024 3D Printing Industry Awards?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows APNAs headquarters in Fowlerville, MI. Photo via Asahi Kasei.

Researchers from John Hopkins University have developed a new 3D printing programming language called Time Code (T-Code). Outlined in a Nature Communications study, co-authors Sarah Propst and Jochen Mueller claim T-Code improves 3D printing speed and quality for complex multi-material parts.Optimized for Direct Ink Writing (DIW) additive manufacturing, this new approach uses a Python script to divide traditional G-Code into two separate tracks. One controls the 3D print path, while the other manages printhead functions.Unlike G-Code, which executes tasks line-by-line, T-Code uses time to synchronize the 3D printers motion with key commands like material switching and flow adjustments. This eliminates common start-stop interruptions that slow production and create defects, enabling continuous, uninterrupted fabrication. As a result, 3D printing becomes faster without losing accuracy or detail, facilitating advanced capabilities like smooth gradients and in-situ material changes.According to the Baltimore-based researchers, their new methodology can handle complex designs that are challenging to achieve with G-Code. T-Code reportedly offers potential across various fields, including biology, electronics, mechanics, and optics. Propst and Mueller believe it could support the production of 3D printed wearable electronics and smart prosthetics. They also emphasize T-Codes ability to accelerate simultaneous manufacturing, offering promise for scaling mass customization.Multi-color 3D printing with T-Code. Photo via Johns Hopkins University.Introducing T-Code: a new programming language for 3D printersG-Code (short for Geometry Code) is the standard programming language for extrusion-based 3D printing. Originally developed for CNC machines in the 1950s, it employs line-by-line execution that requires the 3D printer to decelerate and stop when executing a new command. This slows the 3D printing process and can lead to over-extrusion defects that impact accuracy and precision.In single-material DIW printing, pauses usually happen only when the print path changes direction. However, when adding operations like material switching, additional commands must be inserted into the G-code, which disrupts the extrusion process and increases the risk of defects. By separating auxiliary controls from movement, T-Code ensures that the printhead functions smoothly without interrupting the 3D printing process.How does T-Code work? First, a regular G-Code file containing the desired locations of auxiliary commands is imported into Python. The researchers script separates the movement and auxiliary commands into two groups while keeping them properly aligned.Once decoupled, separate movement commands are merged into a smooth, uninterrupted 3D print path. Next, the Python script calculates the 3D printers speed and velocity to generate a velocity profile. It then determines the exact timings of the auxiliary commands by mapping their location on the velocity profile. These timestamps are formatted into a list, ready for execution. Finally, a signal from the 3D printer executes the script, synchronizing the printhead operations.According to the researchers, this approach facilitates the creation of objects with superior functional gradients. These are difficult to achieve using conventional G-Code, which breaks down the print patch into discrete steps. This means that gradual changes, such as varying the filament thickness, material composition, or UV-curing intensity, are executed in segmented steps, which can lead to defects, long print times, and reduced precision.Using T-Code, however, unlocks smooth, continual adjustments that create multi-material gradients without stoppages. The new approach can also create objects with varying densities or material compositions in specific areas. By precisely controlling the material ratios during 3D painting, T-Code can produce complex parts with graded mechanical, optical, or compositional properties.The new approach has been designed for integration into existing 3D printers without altering the hardware or software. As such, its creators claim that T-Code allows low-cost, desktop 3D printers to produce structures comparable in quality to high-end alternatives. While optimized for DIW, the programming language offers universal compatibility with all applications, materials, and extrusion systems that work with conventional G-Code. This includes FDM technology, high-viscosity inks, and volumetric extruders. It can even be used alongside CNC milling machines and lathes.Propst and Mueller are confident that their approach will be valuable for producing scalable, multifunctional components across a wide range of applications, including biological, electrical, optical, and mechanical fields.3D printing with G-Code on the left and T-Code on the right. Photo via Johns Hopkins University.Research enhances multi-material 3D printingJohn Hopkins University is not the only institution exploring novel ways to optimize multi-material 3D printing. Last year, a team from Seoul National University developed a two-step process to create parts with specific gradient properties in FDM 3D printing.Generally, users cant achieve precise spatial control over material composition with FDM 3D printers because the nozzles can only extrude a single filament at a time. The South Korea-based team overcame this hurdle by fabricating a digital material. This was created by depositing different base materials layer by layer. During extrusion, these materials were homogenously blended in the nozzle, creating functional material gradients in the final part.The research paper, published in Nature, presented a novel blended FDM (b-FDM) process that successfully creates parts with significant property variations. For example, it can combine mechanical strength, electrical conductivity, and color in ways that traditional methods cannot. Importantly, this approach can be implemented using standard FDM 3D printers and filaments, providing a low-cost and accessible means of producing functional gradient materials.Elsewhere, University of Illinois Urbana-Champaign and the Beckman Institute for Advanced Science and Technology developed a chameleon-inspired method for multi-color 3D printing. While most multi-color approaches require multiple materials, this method only needs a single ink, increasing efficiency and sustainability.The teams UV-assisted-ink-writing approach allows colors to be altered on the fly during 3D printing. Changing the strength of the UV-light radiation as it cured an ink made from photo-cross-linkable bottlebrush block copolymers (BBCP) caused the polymers to crosslink in different ways. This translated to a broad spectrum of 3D printable colors, demonstrated by the teams multi-color chameleon image and recreation of Vincent Van Goghs Starry Night painting.Who won the 2024 3D Printing Industry Awards?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows Multi-color 3D printing with T-Code. Photo via Johns Hopkins University.

Ford Motor Company, a global automotive manufacturer established in 1903, is gearing up for its first Formula 1 race in two decades. Official competition begins in 2026, but development is well underway through a partnership with Red Bull Powertrainsthe engineering arm behind Red Bull Racings F1 power units. Over 1,000 3D printed parts have already emerged from Fords additive manufacturing labs, leveraging testing methods adapted from the aerospace sector.Several of these 3D printed components, including cold plates for batteries and cooling plates for other systems, feed into the internal combustion engine and hybrid technology that Ford is developing for the upcoming racing season. Engineers rely on the companys century-long manufacturing expertise to design parts for high-stress conditions. Cross-departmental support, from battery development teams to thermal system specialists, contributes knowledge crucial to refining each design.Effective testing protocols bridge the gap between additive manufacturing and real-world performance. Fords additive manufacturing group measures mechanical strength, hardness, and precise geometry through 3D scanning. Non-Destructive Evaluation experts then use X-ray and CT scanning to generate digital models, revealing internal structures that would remain hidden with conventional inspection tools.Every component receives further scrutiny at the Product Development Centers metrology lab, where final checks confirm dimensional accuracy. Keith Ferrell, who leads Fords additive manufacturing collaboration with Red Bull Powertrains, notes that each step ensures racing parts can handle intense speeds and heat. Were pulling in all of these Ford teams with all of these areas of expertise to help in the program, Hertrich added, underscoring the broad collaboration behind Fords F1 efforts.Many of the new parts go beyond simple items such as fasteners. Its not things like nuts and bolts and easy stuff, said Christian Hertrich, Ford Performance Motorsports Powertrain Manager. These are complex metal and polymer parts that get tested to extremes so they can withstand races that average 200 miles an hour.Lessons learned through motorsport testing are already guiding improvements in Fords consumer vehicle lineup. Engineers on the F-150 program recently uncovered a glue overflow issue in headlampsan elusive flaw that had persisted for months despite traditional inspection methods. By adapting advanced scanning procedures refined for racing parts, the Non-Destructive Engineering team pinpointed the problem within one day, sparing costly repairs and customer complaints.Ford Performance new colalboration with Redbull Powertrain. Photo via Ford.3D Printings Role in Formula 1 Performance GainsMcLaren Racing, a British Formula 1 team, now produces up to 9,000 3D printed parts per year using five Stratasys SLA 3D printers. These machines manufacture front and rear wing components, side bodywork, and scale wind tunnel models. Wind tunnel testing remains critical for refining aerodynamic setups, and McLarens additive manufacturing team reports significant time reductions in part production.Scuderia Ferrari, the most successful team in Formula 1 history, has turned to 3D printing for aerodynamic and powertrain applications. Engineers used 3D printed sensor mounts to analyze front wing performance, securing laser ride height sensors to measure movement under race conditions. These mounts were made from nylon-based polymers using Selective Laser Sintering (SLS) or MultiJet Fusion (MJF), two additive manufacturing processes capable of producing impact-resistant components with fine detail.A 3D printed sensor mount attached to the front of the 2022 Scuderia Ferrari Formula 1 car. Photo via Andrew Cunningham. Ready to discover who won the 20243D Printing Industry Awards?What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured image shows Ford Performance new colalboration with Redbull Powertrain. Photo via Ford.

LOT Polish Airlines has begun installing 3D printed arm caps on its Boeing 737 aircraft.Produced by Riga-based aviation manufacturing firm AM Craft, the new single-piece design replaces conventionally manufactured components with a more durable alternative. This decision comes as part of ongoing efforts to maintain cabin quality while addressing challenges in sourcing replacement parts.As Polands flag carrier, LOT operates over 80 aircraft across Europe, Asia, and North America, but keeping them in great condition has become more difficult due to supply chain disruptions and discontinued components.Adding to the point, Maja Margul, Continuing Airworthiness Junior Specialist at LOT, highlighted that frequent cabin use causes wear, requiring timely part replacements. Some degrade faster than expected, while others become unavailable, leading to procurement delays. To resolve these issues, the Riga-based firm developed a redesigned arm cap manufactured as a single piece to address these issues.LOT Polish Airlines has a long history of leadership in commercial aviation, said Didzis Dejus, CEO of AM Craft. We are proud that we were able to leverage our expertise in design and certification of 3D printed aircraft components to solve their supply chain problem with these arm caps, and we look forward to helping them address additional challenges. For commercial aviation, 3D printing has clearly become a highly impactful technology while no one was looking.Bottom view of arm caps showing (left to right) the part being replaced, the unpainted 3D printed equivalent, and two colors of the final printed part. Image via AM Craft.Enhancing durability and efficiency with 3D printed arm capsAmong the affected components were the economy-class arm caps on LOTs Boeing 737s. The original rubber-and-plastic design often loosened, detached, or cracked at the seat attachment point, complicating maintenance. With replacement parts from the original supplier difficult to obtain, LOT turned to 3D printing for both improved durability and reliable availability.To produce the redesigned arm caps, AM Craft used Stratasys Fused Deposition Modeling (FDM) technology, employing ULTEM 9085 filament, a high-performance thermoplastic known for its strength, flame resistance, and suitability for aerospace applications. The final finish was applied using Mankiewiczs ALEXIT coating system, ensuring a consistent appearance and durability that aligns with LOTs cabin interior requirements.A total of 1,200 arm caps were manufactured by AM Craft for installation across LOT Polish Airlines Boeing 737 fleet. Beyond production, AM Craft also handled the certification process, delivering the components with an EASA Form 1 Airworthiness Certificate, confirming compliance with European aviation safety regulations.By eliminating the multi-part construction, the redesigned arm cap removed the risk of separation between the rubber and plastic layers while also reinforcing the connection point to the seat. The new structure enhances reliability and reduces the likelihood of damage under frequent use.A key advantage of using 3D printing for this component was the ability to manufacture low-to-mid volume parts without the high tooling costs of injection molding or other traditional methods. This flexibility allowed AM Craft to quickly produce the required parts while maintaining high-quality standards.Margul stated that while LOT initially planned to replace only damaged arm caps with identical replacements from the original seat manufacturer, the AM Craft part was such an improvement that we replaced all the arm caps with the 3D printed version.Top view of arm caps showing (left to right) the part being replaced, the unpainted 3D printed equivalent, and two colors of the final printed part. Image via AM Craft.Unique 3D printed aircraft interior partsThis wasnt the first time that the aviation manufacturing firm helped design interior components for an airline. Last year, AM Craft supplied over 300 3D printed blanking panels to Finnair for its Airbus A320 fleet, replacing outdated flip-down video monitors. The upgrade is part of Finnairs effort to modernize Passenger Service Units (PSUs) across 17 aircraft, aiming to reduce weight, minimize inventory, and simplify installation, with each panel taking just 10 minutes to fit.Using 3D printer OEM Stratasys FDM 3D printing and ULTEM 9085 filament, AM Craft tailored the design for easy mounting and finished the parts in its certified paint shop. Installation began in late 2023 and was set to be completed by the end of 2024. Both companies considered the project a success and are open to future 3D printing collaborations.Back in 2021, Senior Aerospace BWT, a UK-based manufacturer of air distribution systems, brought 3D printing in-house to produce aircraft interior components. After two years of testing and qualifying ULTEM 9085, an aerospace-grade thermoplastic, the company installed two Stratasys Fortus 450mc 3D printers at its Cheshire facility.Moving away from external suppliers, the manufacturer began producing parts for low-pressure air ducting and air handling systems used in regional, military, and private jets. Switching from aluminum to FDM 3D printing helped cut weight, cost, and lead times by up to 75%, making it a more efficient option for small, complex components.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows a bottom view of arm caps showing (left to right) the part being replaced, the unpainted 3D printed equivalent, and two colors of the final printed part. Image via AM Craft.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

Where does the application of AI to 3D printing make sense?As previous editions of the 3D Printing Industry Executive Survey identified, the emergence of accessible AI tools and increased investment is set to accelerate broader industrial trends. Optimistically, the confluence of discrete components of the manufacturing and business ecosystem unified by AI tools ushers in a new era of productivity. Taking a more jaded perspective, AI is either the most recent hype train or liable to unleash a digital Sauron.We asked additive manufacturing experts where do they see AI applications having an impact in AM?The range of answers spans the manufacturing ecosystem and touches on many other aspects of business productivity where AI tools may be useful. For example, ChatGPT has enabled what some see as enhanced communication, allowing our global industry to produce written content in a standardized manner or to generate ideas.A counterpoint, one supported by those who decry the encroachment of machines into the realm of human creativity, is that the influx of generic yet verbose, emoji-laden social media posts is of little benefit. Perhaps unsurprisingly, given the contrarian cycle, a backlash against AI-created content, with its highly visible telltale traits, is already fomenting.The written word is not the only domain under threat, one expert warns of copycat and copyright problems for physical parts.We should remember that AI is not monolithic. While certain expressions of AI may be prone to hallucination, lack of social nuance, missing implicit knowledge, or an absence of contextual memory, the resolution of such flaws is not critical for particular strands to be useful.Viewing AI as an enabling technology on the path to industrial-scale production with simulation tools and in situ monitoring ensuring first-time-right builds. One expert summarises the benefit as more time 3D printing, less time tinkering with manufacturers eyes on throughput, indeed this is a goal worthy of pursuit. For fleet-level operations, AI may become vital in aiding predictive maintenance and automated production.Material characterization and material development Next-Generation Chemistry are expected to benefit from AI. The latter may be an idea resisted by some, and whether a computational alloy progresses beyond lab scale production is a non-trivial task to unravel.Design tools whether in the form of text-to-CAD generation, appraisal of existing design repositories to determine fit of AM, build preparation, or optimized complex geometries are all subjects raised by the experts.Once again, this is a long read. Weve included the responses from those who generously gave their time to provide insights; compiling this series is always a pleasure. Perhaps you may wish to bookmark this page and revisit it at leisure.We hope the answers here provide a starting point for a bigger conversation. If youd like to join that conversation, get in touch.Overall, the tone is positive, and to generalize the overall perspective, AI will increase the adoption of AM.All aboard! To the industrial metaverse and beyond!More from the 2025 3D Printing Industry Executive Survey:3D Printing Trends in 20253D Printing Forecast 20303D Printing Industry Economic Outlook for 2025Sona Dadhania, Principal Technology Analyst, IDTechEx3D printing exploded in the early 2010s thanks to its community of tinkerers; however, new users, especially in the industrial segment, want to spend less time tinkering and more time printing parts that are ready-to-go. Where AI could have the most impact is in pre-production and real-time monitoring applications. If AI could be used to identify defects before or during printing and then automatically fix the 3D model or adjust printing parameters without human intervention, then a lot of the labor involved in 3D printing (figuring out how to print well) can be eliminated.Sascha Rudolph, Chief Operating Officer, EquispheresAI applications in Additive Manufacturing will be another enabling technology as the industry accelerates the shift to industrial-scale production, most significantly in AM design and process optimization, workflow automation and supply chain management. Advancements in generative AI tools will fuel the design of highly tailored geometries for AM while training models will help to fine-tune run parameters during the printing process, such as laser power, scanning speed and layer thickness, significantly improving build rates and consistency at higher volumes. We also see AI being used in the development of new and specialized alloys to further enhance the mechanical properties of finished parts. Increasing automation in predictive maintenance and supply chain management will help to ensure maximum capacity for production scale.Dr. Max Siebert, CEO and Co-Founder, Replique GmbHApplications of AI will significantly affect a number of fields. In design, AI is already enhancing how parts are optimized for 3D printing, using design for additive manufacturing (DFAM) tools, and this will only grow.AI will also transform AM process management. It will make quoting more effective and enhance the entire process of choosing materials and technologies. By finding the right print parameters for every structure of the part and the simulation of the print process it will further increase the amount of first-time-right builds. Additionally, it will identify mistakes made during the printing process, guaranteeing improved quality control and fewer defects. This will finally reduce costs of printing. Furthermore, AI will be essential in forecasting demand, assisting businesses in streamlining production plans and inventory control, and reducing waste throughout the process.Nanne Veldman, Vice President, EMEA, UltiMakerAutomatic detection of print failures and identification of their root causes is an exciting advancement in FDM 3D printing. Essentially, this concept mirrors UltiMakers visual troubleshooting guide, where the system analyzes defects and provides clear insights into the likely cause of the issue. By integrating this know-how with AI, you create an automated troubleshooting tool that can identify and resolve problems in real-time. In fact, similar technology has already been implemented, with systems being capable of detecting spaghetti failures and halting the printthis innovation has been around for years.Martin Jewell, CTO, Rapid FusionAI applications are poised to revolutionize Additive Manufacturing (AM) by enabling smarter, more efficient, and highly adaptive processes across several key areas:In-Process Monitoring and OptimizationAI-driven in-process monitoring systems analyze real-time sensor data during printing, enabling closed-loop feedback for dynamic adjustments. This ensures optimal parameters such as extrusion speed, layer height, and thermal settings are continuously maintained. By detecting anomalies and making corrections in real time, AI significantly reduces defects and material waste, while enhancing overall part quality.Advanced G-Code ManipulationAI enables real-time generation and optimization of G-code, tailoring toolpaths for specific material properties, geometries, and process conditions. This ensures precision in material deposition, better thermal control, and improved strength and surface finish, especially for complex designs and high-performance materials.Predictive Maintenance and Smart Machine ManagementAI plays a pivotal role in enabling predictive maintenance by analyzing real-time data from machines to identify wear patterns and potential failures before they occur. This proactive approach minimizes unplanned downtime and extends machine lifespan. Additionally, AI systems can autonomously schedule maintenance, track performance metrics, and optimize machine operations for maximum productivity.Quality Assurance and Process StabilityAI-driven analysis of in-process and post-process inspection data, including thermal imaging and dimensional measurements, ensures every part meets stringent quality standards. Automated defect detection and trend analysis reduce reliance on manual inspections and provide insights into long-term process stability.Smart Factory IntegrationAI enables the seamless integration of AM systems into smart factory environments. By connecting machines, sensors, and production workflows, AI enhances overall manufacturing efficiency. This includes optimizing resource allocation, managing production schedules, and creating adaptive workflows to respond to real-time demand changes. AI also facilitates better collaboration between AM and traditional manufacturing methods, fostering hybrid production approaches.Thermal Management in High-Temperature ApplicationsFor applications involving advanced materials like PEEK, AI dynamically controls thermal inputs, ensuring consistent material properties and minimizing defects. By monitoring and adjusting heat flow, AI improves process reliability and supports the adoption of high-temperature printing in aerospace and other demanding industries.By integrating these AI capabilities, AM is moving toward a future of smarter, more reliable production systems, reducing costs, enhancing part quality, and driving innovation across industries such as aerospace, automotive, and beyond.Mahdi Jamshid, PhD, Director Market Intelligence, Wohlers Associates, powered by ASTM InternationalAI is poised to significantly impact numerous aspects of Additive Manufacturing (AM). Key areas of influence include: Machine health and in-situ process monitoring for real-time feedback and predictive maintenance; Advanced material characterization and inspection, encompassing imaging, analysis, interpretation, and seamless data sharing; Data analysis and management for process optimization and quality control; Material development focused on achieving novel properties, increased processability, and lower production costs; Design optimization through AI-powered tools; Supply chain management optimization; and Streamlined process qualification and part certification.Finally, the development of robust AI models will be significantly accelerated by increased collaboration among organizations. The formation of new coalitions or consortia focused on the generation and sharing of high-quality data for model training will be vital for driving further innovation and accelerating industry growth.Matteo Vezzali, Head of Partnerships, MyMiniFactoryIf we consider AI a statistical model designed to give a result closer to the expectation of the human operator, it can have multiple applications within the realm of AM workflows. From improving features of parametric models to fit into larger assemblies to optimizing supports through machine learning, AI could be a game changer for many workflows.If we consider AI as a creative tool or something to replace creatives or creativity per se, I dont see much use for it as the current tools for 2D images produce interesting results when they fail their mission rather than when they succeed.If we view AI as a statistical model designed to produce results that align closely with the expectations of a human operator, it can offer numerous applications within AM workflows. These applications range from enhancing the features of parametric models to ensure seamless integration into larger assemblies to optimizing support structures through machine learning. AI has the potential to significantly improve efficiency and effectiveness across various AM workflows.Justin Michaud, CEO, REM Surface EngineeringAI would seem to have many potential benefits relative to part design and build optimization as well as for process monitoring.Irma Gilbert, CEO, Autentica Car partsAI will play a transformative role in additive manufacturing (AM) by enabling the creation of a decentralized AI digital manufacturing infrastructure combined with Web3-powered e-commerce marketplaces for 3D printing allocation and decision-making.This integration empowers a decentralized, intelligent supply chain where AI algorithms optimize the production, allocation, and distribution of 3D-printed parts in real-time. By analyzing demand patterns, material availability, and manufacturing capacity, AI can dynamically allocate production tasks to qualified manufacturers while ensuring cost efficiency and reduced lead times.Moreover, integrating Web3 technologies with AI ensures secure, transparent transactions and protects intellectual property during part design and distribution. Together, these innovations create a more resilient, scalable, and sustainable framework for additive manufacturingone that brings greater trust, efficiency, and flexibility to the industry.Stefan Ritt, Owner and founder, AM/3D printing concepts & market integrationAI will very fast become a double-edged sword, so to speak, for AM. On one hand it will be very helpful to erase common errors in building processes and operations through analysis of big data volume (if made available!) and help to design new polymer mixtures and metal alloys or composites. On the other hand, it will require less experienced engineers or designers to create working products. Copycat and copyright problems for parts and processes will become a more prominent problem. AI will then enable or at least simplify the design and production of restricted items in various fields. This has to be seen as a threat to communities and needs to be addressed smartly.Vincenzo Belletti, Director of EU Public Affairs, CECIMO European Association of Manufacturing TechnologiesAI applications can bring added value to additive manufacturing (AM) by significantly improving quality, speed, and efficiency across the production lifecycle. AI-driven solutions can accelerate AMs integration into broader manufacturing workflows, enabling seamless and efficient operations. Among its applications, advanced AI inspection systems can provide real-time quality monitoring, ensuring that AM components consistently meet rigorous industry standards.This level of control will have a major impact on reducing defective output, increasing first-time-right production rates, and enhancing the overall reliability of AM processes. As AM technology matures, the integration of AI will enhance the reliability and consistency of AM processes, making it a more dependable technology and accelerating its adoption across diverse industries.Franco Cevolini, CEO and CTO, CRP TechnologyArtificial intelligence is a transformative force in additive manufacturing. One of its most impactful applications is in design optimization, where AI-driven generative design is creating highly efficient and lightweight structures. These designs are particularly beneficial in industries like aerospace and transportation, where performance and weight reduction are critical.AI is also streamlining production processes by enabling real-time monitoring and optimization of machine parameters. Predictive maintenance, powered by AI, is reducing downtime and ensuring consistent quality in manufacturing operations. Furthermore, AI is accelerating material innovation by analyzing vast datasets to identify new formulations, enabling faster development cycles and more precise material properties.The ability of AI to drive collaboration across industries is equally significant. Partnerships between 3D printing providers and sectors such as space exploration, automotive, or renewable energy are fostering groundbreaking developments. By leveraging AI, these collaborations are pushing the boundaries of whats achievable and unlocking new opportunities for innovation.Finally, AI is shaping the future workforce by enhancing the tools and technologies available to engineers and designers. By providing insights into design, materials, and processes, AI is empowering professionals to deliver personalized solutions at industrial scales, ultimately ensuring that additive manufacturing remains at the cutting edge of technological progress.Alex Hussain, CEO, 3DChimeraAI has tremendous potential to revolutionize additive manufacturing, and its impact will be felt across multiple levels, from machine operations to design optimization.At the machine level, AI will play a critical role in detecting failures and making real-time adjustments to production parameters. Initially, this will be driven by simple sensor data, such as environmental temperature or humidity, but it will quickly evolve to include camera-based monitoring and, eventually, 3D scanning capabilities. These advancements will enable printers to self-correct, improving reliability and reducing waste.In the print setup process, AI advisors will become integral to slicer software, guiding users through complex decisions such as print parameters, part orientation, and layout. These tools will optimize for print speed, quality, strength, and part finish, making additive manufacturing more efficient and accessible to a broader audience.Looking further ahead, AI will enable design optimization for additive manufacturing (DfAM). Imagine taking a part designed for CNC machining and running it through an AI algorithm that reimagines it for FFF or SLS technologies. The result would be different but functionally equivalent parts, each tailored to the strengths and constraints of their respective processes. This capability will unlock new opportunities for innovation and help industries maximize the potential of additive manufacturing.AI will fundamentally change how we approach additive manufacturing, driving efficiency, reliability, and creativity across the board.Alexandre Donnadieu, Chief Commercial Officer, Chief Commercial Officer, 3YOURMINDAI is emerging as a game-changer for additive manufacturing, addressing some of the most persistent challenges while unlocking new opportunities. Its applications span the entire lifecycle, from design to production and materials development.Augmented DesignersOne of the most immediate and impactful applications of AI is in augmenting the design process. Generative AI will play a critical role in enabling faster and more efficient creation of 3D designs, as well as optimizing those designs for additive manufacturing. Design complexity remains a bottleneck for widespread AM adoption, but AI-powered tools can lower this barrier by making design more accessible and accelerating the path from concept to production.Zero-Defect ProcessesAI will revolutionize production processes by providing real-time control and monitoring, as well as predictive capabilities to anticipate and mitigate defects. This will not only improve part quality but also streamline the qualification process, which is often lengthy and data-intensive. By leveraging data-driven pre-qualification, manufacturers can reduce lead times and costs, enabling faster and more reliable production.Next-Generation ChemistryAI will also have a profound impact on research and development, particularly in the realm of new material innovation. Through advanced simulations of material properties, AI can accelerate the customization of materials for specific applications in industries such as medical, aerospace, and electronics. This capability will open the door to entirely new use cases, allowing additive manufacturing to solve challenges that were previously out of reach.As AI continues to evolve, it will drive greater efficiency, precision, and innovation in additive manufacturing. The integration of these technologies will redefine whats possible and open new frontiers for industries leveraging 3D printing.Rob Higby, Chief Executive Officer, Continuum PowdersAI will play a transformative role in additive manufacturing. It is already having an impact in areas such as design optimization, predictive maintenance, and quality assurance. In the future, AI will enable smarter material selection, real-time process monitoring, and enhanced efficiency, allowing manufacturers to minimize waste and maximize performance. This shift will drive innovation and sustainability across advanced manufacturing.Dr. Wilderich Heising, Partner & Director, Boston Consulting Group (BCG)I see two main areas, where AI will make a difference in the AM industry. First, generative AI capabilities will boost the design processes by leveraging generative design and topology optimization. We will be able to design faster, more efficient, and with better outcomes. Second, we will see more and more equipment providers using machine learning and in-line quality control and detection powered by AI to increase reliability and reproducibility of print jobs.Henrik Lund-Nielsen, Founder & General Manager, COBOD3D Printing enables cost-efficient construction of AI-generated design, which would be cost-prohibitive with conventional construction methods.Dr. Jeffrey Graves, President & CEO, 3D Systems, President & CEO, 3D SystemsI believe AI will directly impact the efficiency of 3D printing through incorporation of sensing and automated in-process data collection which will feed rapid, large-scale data analysis and real-time optimization of the process. At a fleet level, AI can make large impacts in machine up-time and automated operation, as well as optimization of the full-work flow. I anticipate this will lead to step-function changes in part quality and throughput, decreasing component costs and reducing risk of adoption in high-reliability applications.Dayton Horvath, Director, Emerging Technology and Investments, AMT-The Association For Manufacturing TechnologyAI applications in AM fall into two representative categories today: the first is interface augmentation and the second is a complement or alternative to modeling and simulation tools. The AM technology stack requires human interaction at every major step; AI can serve as an accelerant by changing the medium of interaction, length of the interaction, or impact of the interaction. When using AI as a tool to improve the technology directly, opportunities exist where physics-based modeling or simulation falls short in efficacy, efficiency or cost. In the case of efficacy, certain data problems do not have easily correlated physical models and gives AI tools a chance to shine.Rob Lent, Chief Operating Officer, Vision MinerAI has shown it can handle complex tasks in no time, and were starting to see that impact manufacturing too. Manufacturing is still both an art and a sciencewhere the craftsman is the artist, and experience makes all the difference. Right now, that experience is critical. But in the coming years, I expect it to matter less for making parts. You might not need the expert who knows every detail about a tricky thermoplasticAI will step in to fill that gap.Giles Gaskell, Additive Industry Specialist, Pinnacle X-Ray SolutionsAI has the potential to combine data from in-line process monitoring and continuous real-time independent inspection methods to close the quality feedback loop, bringing us closer to making perfect parts, every time.Stephan BeyerAI is instrumental for the value creation of 3D printing. It starts with automation, optimization of file, uptime of machine, and lowering cost. A trend we see in traditional manufacturing for years now.Ric Fulop, Founder and CEO, Desktop MetalAI is already heavily used in shape compensation in sinter based processes and thermal stress simulation in melt based processes. I expect we will see it heavily used in CAD and other content creation tools. This should increase demand for AM products.Harshil Goel, Founder and CEO, DyndriteI believe the applications of AI are over blown at the moment. There will be applications of image recognition, linear algebra and statistics to make better parts faster through thermal management. The folks using AI right now are in my opinion engaged in marketing.Dyndrite has an AI strategy to be made public at a later date. In the meantime, quite a bit needs to happen before AI can do anything interesting.Paul Bullock, Director / Owner, 3D 360Improvements to quality and in-process monitoring. AI will also lead to more flexibility and what is able to be 3D printed.Fabio SantAna, Director, Farcco TecnologiaDesign, Faster Simulations, Better ProcessesJeremy Haight, Chief Principal Engineer, Vestas Wind Systems A/SIn the near-term, I see AI having the biggest application in in situ process monitoring and error mitigation. In the long term, I see AI having a wide range of applications such as: LLM (large language model/conversational AI)-to-solid model, automated process and MES optimization, automated applications selection (PLM-to-DfAM), embedded CAD/CAMAM recommendations with automatic topology and process optimization. This is not even to speak directly to the many industry specific applications such as those in healthcare, aerospace, energy, etcJonathan Beck, Founder/Manager, Scan the World / MyMiniFactoryAI will develop further into generative design, from design to production and post-processing. Currently a lot of wasted materials and time, risking becoming less cost effective than other manufacturing industries. AIs ability to optimise design, monitor production processes and automate post-processing will hopefully make AM more agile, cost effective and scalable, allowing for innovation and users of all abilities to contributeThomas Batigne, Co-founder & CEO, LynxterAI will serve as a valuable assistant for designers and manufacturers, reducing the labor intensity of tedious tasks, streamlining operations, and enhancing creativity. It can be particularly useful in additive manufacturing (AM) for nesting and printing profile optimization, as well as for analyzing print data and reports.Aurlien FUSSEL, Innovation Program Manager, ALSTOMWhile the immediate impact of AI applications in additive manufacturing (AM) may seem limited, prioritizing intelligence can unlock new possibilities. Geeblees innovative French solution stands out by aggregating constraints to design unique part shapes, thereby pushing performance boundaries to achieve unprecedented outcomes in AM.Dr. Vincent Morrison, CEO, NEW AIM3D GmbHWe will see AI technologies in data preparation and preprocessing in the next few years, which will then make the use of the machines faster and easier for the end users.There will also be a great opportunity in the fact that AI technologies will accelerate the development of AM equipment, as it will massively speed up the programming of equipment and processes, creating new space for machine and process innovation. This is already happening today.The last step, which in our view is still a long way off, is the extensive integration of AI into the machine control of extrusion systems. This is where high demands in terms of data volume and processing speed currently come up against insufficient computing power in the field of industrial control systems.Sascha Schwarz, CTO, TUM Venture LabsPhysics-informed AI algorithms, not just rule-based software, will finally enable the AM user to master the complexity of the multi-modal parameter space on the process level and also unlock the relevant generative designs capable of taking over the intended function in the real physical environment, such as thermal management in complex technical systems.Adam Penna, Founder, All Digital Additive ManufacturingAI applications are set to revolutionize Additive Manufacturing (AM) in numerous ways. Firstly, AI can optimize the design process by incorporating AM-specific parameters, enabling generative design, and optimizing topology for efficient production. In material development, AI helps create customized materials that enhance performance and broaden the range of AM applications. Process optimization is another area where AI shines, providing real-time control and adjustments to ensure optimal printing conditions. Quality assurance benefits from AI through advanced vision systems that detect defects in real-time, resulting in higher accuracy and reduced waste. Predictive maintenance, powered by AI, identifies early signs of equipment issues, thereby reducing downtime and extending the lifespan of AM machinery. Additionally, AI streamlines supply chain management, optimizing logistics, and reducing inventory costs.These AI applications significantly enhance the efficiency, quality, and innovation in Additive Manufacturing.Dr. zlem Weiss, General Manager, Expertants GmbHAdditive manufacturing is most profitable when a single print job can repeatedly produce many customized parts. AI will play a key role in achieving this in a stable and most efficient way! New models will be created based on the data set of today and will help streamlining and standardizing design of parts. Data mining and monitoring process parameters will enable robust manufacturing and post-processing.I dare to go as far as to say that it will be AI that will close many gaps and finally enable additive manufacturing to take its place alongside all other manufacturing methods.Slobodan Ilic, Sales & Marketing Director, BLT Europe, Bright Laser TechnologiesI believe AI can make a significant impact on additive manufacturing across three major areas.The first is design. Here, AI can be used to support innovation and enable full customization by optimizing designs specifically for AM. This opens the door to creating parts that were previously impossible to manufacture.Next is quality control, where AI offers powerful tools to monitor, interpret and adjust process parameters in real-time. By integrating data from various sensors and quality assurance systems, AI can identify and correct issues as they arise. A major hurdle for this is the lack of structured and classified data, which is essential for AI to reach its full potential in this area.Lastly, AI can work in parallel with AM processes to streamline manufacturing operations, procurement and strategic management. This can lead to more efficient production workflows, better resource allocation and improved decision-making at every level of the manufacturing process.Ian Falconer, Founder & CEO, Fishy FilamentsAutomated NDT, which is directly analogous to medical imaging, so could be co-developed. Design optimisation is already there in FEA, but it could be radically democratised by AI.Rudolf Franz, CEO, voxeljetAI will transform AM through process optimization, generative design, and predictive maintenance. AI-driven analytics will improve part quality, reduce defects, and boost efficiency. Generative design tools will unlock optimized geometries for 3D printing, enhancing performance. Predictive maintenance will reduce downtime and improve reliability.Maxence Bourjol & Kareen Malsallez, Head of Sales & Marketing Manager, 3DCeram SintoAI is already making significant inroads in ceramic 3D printing. In our case, weve been developing AI solutions for three years now. Weve structured our AI assistance in two key phases: pre-process with CERIA Set, which provides design guidance and custom parameter generation, and on-process with CERIA Live for real-time control and optimization. This dual strategy directly addresses what matters most to manufacturers achieving cost-effective production and optimal productivity.Were continuously expanding our AI databases to optimize the printing process, ensuring our partners can maintain competitive production costs in their markets. This isnt just about having AI capabilities its about developing tools that guarantee profitability for our industrial partners.The impact of AI on productivity is transformative, and process providers who havent started integrating AI solutions risk falling behind. As we are now in 2025, were focused not just on producing quality parts, but on ensuring our partners achieve meaningful returns on their AM investments through AI-driven optimization. This is how were shaping the future of ceramic 3D printing: by making industrial-scale AM both possible and profitable.Gil Lavi, Founder & CEO, 3D AlliancesIntegrating AI into additive manufacturing offers numerous benefits, including enhanced efficiency, innovation, and scalability. One of the primary areas of focus is leveraging AI to optimize the design of components for various AM technologies. Over time, AI has the potential to achieve maximum optimization of designs before printing, ensuring superior performance and resource efficiency. This capability will be particularly critical as AM becomes more integrated into manufacturing processes.Ma Jingsong, GM, Uniontech3D printing is like a glimmer of light, bursting into a new life for the industry. Under the demonstration effect of metal printing application breakthroughs and market coercion, relying on the rise of AI, as well as the penetration of the digital wave in the consumer end, more and more manufacturing enterprises will actively embrace 3D printing technology to help the renewal of the consumer market and transaction efficiency. UnionTech will continue to take 3D printing as the main technical carrier, through continuous technological innovation and application innovation, to build a high delivery capability of digital manufacturing in small-batch scenarios, and achieve the replicability, transferability, and connectivity of this capability.Sherri Monroe, Executive Director, AMGTA Additive Manufacturer Green Trade Assn.Some specific areas within the use of AM where I expect to see AI impacts are: Highly optimized designs, material and energy usage Matching of opportunities to transition waste and by-products into assets and resources connecting who has it to who wants it Streamlined and more efficient processes for production and distribution More intelligent business models that leverage AM-enabled production distributed across geographies, time, and designs for economic and environmental outcomesAndre Wegner, CEO, AuthentiseIn the near term, AI will help in the following ways:1) Documentation and Certification: Were going to make the tedium of AM, like getting certification approved. ThreadsDoc is already doing this for Boeing.2) Identifying AM Applications: Were still struggling to find parts or assemblies where additive manufacturing can be useful. AI can change that by quickly and effectively reviewing massive amounts of datadesign intent, material properties, and performance needsand its a powerful tool for helping us decide where AM adds the most value.3) Empowering Operators: AI can be like a co-pilot for AM operators. It provides real-time guidance, suggesting machine settings, adjusting process parameters, and even flagging potential defects before they happen. This is not replacing operatorsstandards and common sense require them to always be in the loopbut whether visual or text-based AI, it will play a role.Brad Rothenberg, CEO, nTopAccelerating simulation and calculation of manufacturing / build parameters.Joseph Crabtree, Founder and CEO, Additive Manufacturing Technologies (AMT)AI applications are set to revolutionize additive manufacturing by streamlining processes and enhancing efficiency. Collaborations like AMTs work with NVIDIA and HP highlight the transformative potential of AI in areas such as automatic file generation, optimized printing strategies, and seamless post-processing of 3D parts. These advancements not only reduce human intervention but also improve part quality and production speed. By leveraging AI-powered tools, additive manufacturing is moving closer to achieving fully integrated and automated workflows, which will be critical for scaling production and meeting the growing demand for precision and customization in industries such as aerospace, healthcare, and automotive.Marleen Vogelaar, CEO, ShapewaysAI is a catch all term for a number of different processes and technologies, some of which are already well known to AM (and the wider manufacturing industry) and some of which are emerging as potentially useful. Machine learning, computer vision, large language models, neural networks these and more are all part of the AI conversation.All in all, AI is poised to have profound impacts across the entire AM process chain. From ideation, design, model preparation, print setup, monitoring, correcting, etc etc. Of these (without any timeline!) we can expect to see AI:Accelerating ideation and designGenerative design tools powered by AI will start to create complex geometries optimized for 3D printing, significantly reducing design timelines. Integrated into major CAD platforms or through standalone tools, these systems enable designers to explore multiple solutions rapidly. By leveraging deep learning models and large datasets, AI will identify the most efficient designs, offering engineers the freedom to innovate without being constrained by traditional design limitations.Moreover, AI-powered predictive analytics tools analyze designs for potential print issues before production begins. Physics-informed AI can already simulate builds, predict failures, and recommend adjustments, reducing costly trial-and-error cycles.Optimizing material and build parametersAI can play a critical role in material selection and process definition. Machine learning models analyzing vast material datasets and past build outcomes will more widely be used to predict how specific materials will behave under different conditions. This will allow manufacturers to make data-driven decisions, ensuring material compatibility with the desired application while reducing waste.Additionally, AI helps define optimal build strategies, including part orientation, support structure design, and printing parameters. To an extent this already happens (and we dont call it AI, maybe just an algorithm). Predictive scheduling tools further optimize workflows by determining the best sequence for print jobs based on material availability, machine readiness, and deadlines.QA and process monitoringReal-time monitoring technologies, use computer vision and deep learning to inspect every layer of a print for defects. These systems flag issues like warping, layer shifts, or irregularities as they occur, enabling corrective action during the build process. This prevents material waste and ensures higher consistency in final parts.Post-build, AI-driven inspection tools automate quality checks using computer vision to identify defects faster and more reliably than manual inspections. These systems reduce human error, ensure compliance with specifications, and streamline workflows.Post-processing and workflow automationRobotic systems equipped with AI will increasingly automate tasks like support removal and surface finishing, ensuring consistent results. By standardizing these labor-intensive processes, manufacturers will achieve higher throughput while reducing variability and labor costs.Predictive maintenanceBy using IoT-enabled sensors and machine learning algorithms, AI will monitor machine health, predicting when maintenance is needed before a breakdown occurs. This proactive approach will reduce unplanned downtime, lower repair costs, and extend the lifespan of expensive AM equipment.Search & DiscoveryAn additional application is search technology for end users; Thangs 3D for example, leverages cutting-edge AI to revolutionize how users find and work with models. With advanced text, 2D image, and patented 3D search capabilities. This makes it effortless to locate exact or similar models, even identifying parts within parts. AI 3D search capabilities make it possible to analyze 3D mesh and geometry in real time to deliver search results of geometric matches or visually similar models. This innovation streamlines discovery and opens up new possibilities for design efficiency.Shon Anderson, CEO, B9CreationsArtificial intelligence is poised to play a transformative role in additive manufacturing, fundamentally reshaping how we design, produce, and scale parts. From machine learning to expert systems, AI will not only enhance technical capabilities but also make additive manufacturing more accessible and intuitive for a broader range of industries and workforce levels.One of the most immediate impacts of AI lies in optimizing the layout, orientation, and printing of parts. Machine learning algorithms can analyze a vast array of geometries, materials, and production requirements to determine the most efficient configurations automatically. This means faster print times, reduced material waste, and improved part performanceall of which directly benefit the bottom line.AI also enables predictive analytics and real-time monitoring, ensuring process reliability and consistency. By analyzing data from sensors during the printing process, AI can identify and correct deviations before they result in defects. This level of automation not only enhances quality assurance but also builds trust in additive manufacturing as a reliable production method. At B9Creations, weve already implemented real-time 3D printing adjustments into our technology that account for machine tolerances, material chemistry, light output, and part geometry to ensure high CAD fidelity and high consistency part-to-part and printer-to-printer. As a real-world example, for one of our aerospace partners, we are holding +/- 12 micron tolerances on a foot tall part across 50 machines, with interchangeable resin vats and build tables, all managed by our QA/QC toolset.Another critical area where AI will have a profound impact is workforce training and adoption. Expert systems can make complex parts of the additive manufacturing process invisible by automating tasks that currently require significant expertise. For example, AI can handle intricate design adjustments, slicing optimizations, or post-processing recommendations, allowing users to focus on broader goals rather than technical minutiae. This democratization of additive manufacturing will help companies scale their operations by reducing the learning curve for new team members and enabling wider adoption across industries. In dental, aerospace, and jewelry, B9Creations has already leveraged this capability to go directly from a scan or design file to an STL loaded on a printer, making the CAM portion invisible to the user.AI will also play a key role in expanding the applications of additive manufacturing. Generative design, powered by AI, is already enabling engineers to create innovative geometries that were previously unthinkable. As these tools become more sophisticated, well see entirely new product categories emerge, pushing the boundaries of what AM can achieve.Finally, AI will be integral to integrating additive manufacturing into larger manufacturing ecosystems. By connecting additive manufacturing workflows with supply chain management, ERP systems, and predictive maintenance platforms, AI will enable seamless end-to-end operations. This integration will allow companies to better align production with demand, reduce lead times, and respond more flexibly to market changes.In summary, AI is not just a tool to enhance additive manufacturingits a catalyst for its evolution. By making processes smarter, more reliable, and more accessible, AI will drive the industry toward greater efficiency, scalability, and innovation, ensuring additive manufacturings continued growth as a cornerstone of advanced manufacturing.Mike Seal, General Manager, MegnajetAs with some current 3D printing software systems telling the system which forces are involved and leaving the system to extrapolate the best output has resulted in some very organic-looking and perfectly functional prints. AI and or machine learning will enable even less expertise in final design allowing focus on concept rather than complexity. Hopefully, this will lead to some truly inspired and original solutions not limited by what has gone before.Andy Davis: Director of Government Solutions, The Barnes Global AdvisorsAIs strongest advantage is its ability to extract insights from large, complex data pools, enabling human-in-the-loop decision-making. AI processing of datasets will lead to more robust and scalable AM processes, while human oversight ensures validated insights and trustworthy results. Applications for this combined teaming model often called intelligence amplification will include rapid assessments of existing bills of material for AM part selection, engineering and design optimization, faster development of build parameters and processes leading to lower cost and shorter qualification cycles, the correlation of repair and overhaul data with non-destructive testing (NDT) and in-situ monitoring data. In addition, as the data pools for in-service parts grow, AI will be key to the identification of optimal design features by analyzing field service data logs for super-performers, linking them back to design and material decisions.Julien Lederman, Interim CEO, Nano DimensionI think we can expect more precise simulations when it comes to parts, thanks to specific AI algorithms. Also, for general production workflow and continued throughput, AI is proving its worth in ensuring production monitoring solutions are delivering manufacturers critical insight from the factory floor including AM platforms. This is changing things insofar as preventative maintenance and enabling manufacturers to better avoid downtime and its associated costs.Additionally, just as it is in other industries, I think we can expect to see AI help manufacturers automate difficult jobs, make intelligent decisions, and drive efficiency. It could also help drive 3D printing forward by enhancing designs, checking the quality of parts, and enabling more scalability across production.Max Funkner, Founder, 3DWithUsIn the consumer market, with more powerful processors and AI-enabled computers, companies are likely to accelerate the development and training of their own AI systems, integrating them to optimize generators for 3D printing design. Following the emergence of multiple 3D model generators in 2024, we can expect more improvements and advancements in this area in 2025.Kevin Wang, Co-founder and VP, ElegooAI is set to revolutionize the 3D printing experience by making it more precise, efficient, and accessible than ever before. Our Saturn 4 Ultra is equipped with an intelligent detection system that automatically identifies and resolves common printing issues in real time. This feature enhances the reliability of the printing process and empowers users regardless of their technical skill level to achieve professional-grade results.We are actively exploring partnerships with AI companies to further integrate AI into 3D printing. Imagine the ability to generate 3D models using AI, making the technology even more accessible and allowing a broader audience to engage with 3D printing.Dr. Johannes Homa, CEO, LithozAI is sure to play a transformative role in additive manufacturing (AM). By making design processes more accessible, AI is enabling a wider range of users to create optimized models, lowering the barrier to entry for innovation. In addition, machine learning leverages big data to detect patterns and identify errors in prototypes, which will significantly reduce the time and cost associated with trial-and-error iterations.AI is also accelerating the path to serial production by streamlining workflows and optimizing manufacturing processes, ultimately making production faster and more efficient. As AI continues to advance, its integration into AM will unlock new possibilities for scalability and precision.Graham Tweedale, Chief Operating Officer, XaarHistorically, one of the primary challenges in additive manufacturing has been the complexity involved in creating printable models, which often require specialised devices and technical expertise. However, the advent of AI tools is significantly lowering these barriers. AI streamlines the design and preparation of models, making it accessible to a broader audience. This shift is likely to facilitate greater adoption of additive manufacturing technologies across various industries, enabling more users to leverage these innovative solutions.Louise Callanan, Director of Additive Manufacturing, RenishawArtificial intelligence (AI) has the potential to revolutionise AM, particularly in process optimisation and defect prevention. As the technology matures, we expect to see AI become more embedded within AM workflows, leading to improvements in efficiency, quality assurance, and predictive maintenance.Chevy Kok, Vice President, APAC, UltiMakerAI has the most potential in the pre-3D printing stages of (1) material selection, and (2) print preparation. Being able to identify and fix problems at a much earlier stage of the workflow will bring about the greatest savings in the 3D printing workflow.AI in material selection could be a GPT-style coach to help engineers choose the right materials for their applications. Material selection is one of the biggest challenges faced by todays users, as the knowledge of FFF materials is still limited.AI in print preparation stage could be a guide to help users achieve the right 3D print properties by suggesting the right slicer settings to achieve prints based on the outcome that they want, for example, profiles for engineering parts, profiles for visual models, etc.James Franz, President, AMER, UltiMakerThe immediate use of AI in AM will be primarily supporting functions such as software development and customer service. AI can streamline issue resolution, automate code development, and improve efficiency.Another area where AI can make an impact is optimizing the printing process by leveraging data from printers and large-scale data sets. For example, AI can help enhance the way we use printer puts and sensor data to fine-tune the output, whether by adjusting settings in the slicing engine or optimizing machine parameters. Currently, most of the review happens at the end of the print, which allows for analysis and improvements for future prints. But what if the printer can adjust settings in real-time or before a print even starts? As you prepare your model, AI can analyze factors like support structures, orientation, and settings based on specific print goals. This can be done by processing large data sets of past prints. Then during the print itself, AI can leverage sensors on the machine to dynamically adjust factors such as nozzle temperature, flow speed, and other variables to ensure optimal print and reduce errors. In both cases, AI can help to anticipate and correct potential issues, ensuring the highest quality result.Simon Duchaine, Chief Commercial Officer, Dyze DesignAI will play a transformative role in advancing additive manufacturing (AM), addressing some of its most persistent challenges. One of the primary hurdles blocking broader adoptionparticularly in Material Extrusion (MEX)is the lack of process reliability. Unlike traditional subtractive manufacturing, which has matured into a highly predictable and repeatable process, AM often struggles with inconsistencies that hinder its use in production at scale.AI has the potential to revolutionize this by enhancing reliability and repeatability across the AM workflow. Through real-time monitoring, advanced data analysis, and predictive modeling, AI can help identify and correct issues during the printing process, significantly reducing defects and ensuring greater consistency. This progress could also pave the way for additive manufacturing to meet stringent certification standards that currently remain out of reach due to repeatability concerns.In the long term, AI-driven insights will enable smarter, more automated decision-making in design, material selection, and process optimization. By integrating AI, manufacturers can reduce the trial-and-error aspect of AM, streamline production, and unlock new opportunities for AM to serve as a reliable tool in large-scale manufacturing.Glynn Fletcher, President, EOS North AmericaAM is digital-first process, and offers fertile ground for AI applications. Generative design, process monitoring, and predictive maintenance are example processes where AI can optimize efficiency, reduce waste, and enhance product performance. AIs potential to collect and manipulate information to mitigate specific AM challenges shows real promise.Gleb Gusev, Chief Technology Officer & Co-founder, Artec 3DWith AI, photogrammetry can reconstruct objects, areas, and people with unprecedented quality. Excitingly, AI photogrammetry has the potential to open 3D scanning to an entirely new user base, as its compatible with any smartphone or DSLR camera.There are many scenarios where utilising this technology alongside traditional 3D scanning would help you get the best out of both. For example, you can capture an object with a 3D scanner, then reconstruct the entire surrounding scene with AI photogrammetry. In future, I believe these algorithms will get better and faster. Already, these algorithms can handle shiny, semi-transparent, and featureless surfaces areas where traditional photogrammetry struggles. AI-powered reconstructions will only get more accurate. I anticipate that they are going to liberalize 3D scanning and open the technology to new markets.John Kawola, CEO, Boston Micro FabricationAs AI-driven capabilities continue to impact almost all industries, techniques and workflows, demand for smart solutions will rise. In the 3D printing industry, AI will be able to help users optimize processes, make data-informed decisions, improve design and speed-up development timelines. Additionally, next-generation technologies embedded in consumer goods, like smart glasses, will require both high precision and micro-manufacturing solutions to carry out production of the tiny technology that forms these goods.Nick Allen, Founder & CEO, 3DPRINTUK[AI will be used] everywhere. Manufacturing is a slow-to-adopt industry, you can see this with the actual take-up of AM as a manufacturing process in the entire ecosystem. This will likely be the same in AM for AI, but those who do adopt will be the ones who reap the greatest rewards. Efficiency is the key driver to reducing costs, reducing costs is the key driver to product viability, product viability is the key driver to grown. AI may be the driver to efficiency, meaning AI will likely be the root cause of growth for AM.Julien BARTHES, CEO, 3Deus DynamicsI see AI being used for design optimization, better definition of process rules and cost optimization.Ralf Anderhofstadt, Head of Additive Manufacturing, Daimler Truck AG | Daimler Buses GmbHAI offers great potential for additive manufacturing from different directions. However, it remains to be seen what AI will look like in the coming years, as the valley of tears has not yet been reached. If this is not achieved or quickly exceeded, AI will revolutionise additive manufacturing not only in terms of design. This also offers great potential for digital AM business models in particular, as we already see in the successful integration into our digital warehouse and our software-as-a-service solution.Craig Monk, Founder, 3D Print Monkey/Liquid Models 3DI see artificial intelligence significantly impacting additive manufacturing by improving efficiency, precision, and scalability. AI-driven design tools, such as generative design and topology optimization, are already enabling the creation of lightweight, complex structures that reduce material use while maximizing performance, and this will only get better over time. Machine learning and predictive analytics enhance process reliability by reducing downtime and ensuring consistent quality through predictive maintenance. In production, AI is and will continue to optimise 3D printing parameters in real time, improving both speed and accuracy while minimizing waste. Post-processing and quality assurance are also becoming more streamlined with AI automating workflows and inspections. These applications are steadily transforming additive manufacturing into a more efficient and intelligent manufacturing process.Daosheng Cai, Chairman, EASYMFGArtificial intelligence will be integrated into the entire process of AM technology, including data acquisition, process control, simulation optimization, and more. Naturally, the first area to benefit will likely be data acquisition.Dr. Karsten Heuser, VP Additive Manufacturing & Head of Company Core Technology Advanced Manufacturing & Circularity, Siemens AGArtificial Intelligence (AI) is set to revolutionize every aspect of additive manufacturing (AM). One of the most significant impacts will be in the design of better machines using industrial AI. This technology will streamline and accelerate the design and engineering workflow, making these processes much faster and more automated.Industrial AI will act as a major co-pilot for designers, simplifying complex tasks such as topology optimization, fluidic optimization, and other forms of functional integration. This will make it easier to realize advanced designs and improve overall efficiency.The industrial metaverse will also become increasingly relevant for AM, leading to immersive and adaptive 3D printing workflows. This virtual environment will allow for more intuitive and flexible manufacturing processes.Furthermore, industrial AI will enhance the robustness of AM processes. By utilizing in situ data and sensor analytics at the industrial edge, close to the machines, AI will enable real-time monitoring and optimization, ensuring higher quality and consistency in production.Kris Binon, Managing Director, AMISAI is and will be confronted with the same hurdles as AM itself: can you trust the outcome? Can you prove that you can trust the outcome? And AI, too, will be driven by the viability of its business cases. This being said: AI could have significant added value in each step of the process: from design, over (print and part) simulation, to nesting, positioning, etc At first (again, as with AM itself), this will be in high-end applications where the extra investment (training the AI, scrutinizing/validating the outcomes, ) outweighs the cost.Sarah Jordan, CEO, SkuldMany areas, especially in eliminating non-value added. Lean definition- what customers wouldnt want to pay you for if the task was separately itemized.Angel Llavero Lpez de Villalta, CEO, MeltioArtificial intelligence will allow us to eliminate one of the main barriers that was the process, control, accessibility and the use of qualified personnel. In recent years additive manufacturing of metal has been dominated by highly skilled jobs and now we will be able to minimize and we will be giving more robust and simpler processes that can be solved more effectively and on the fly.Bart Van der Schueren, CTO, MaterialiseAI will play a pivotal role in addressing complexity and generating valuable insights in additive manufacturing. By nature, 3D printing is a highly complex technology, with numerous factors influencing the process and final outcomes. AI, including generative AI, has the potential to unravel this complexity by identifying key variables and offering actionable insights to optimize the process, enhancing efficiency, quality, and repeatability.Another significant impact of AI will be in mitigating the industrys skills gap. The current shortage of expertise and skilled professionals is a major challenge for scaling 3D printing operations. By harnessing AI, we can enable qualified engineersbeyond just domain expertsto contribute effectively to AM workflows. For instance, at Formnext, Materialise announced the opening of Magics algorithms via an SDK to facilitate custom workflow development. However, even with these advanced tools, creating the most optimal scripts can still be daunting. This is where AI can step in, simplifying complex scripting tasks and making advanced capabilities more accessible to a broader range of professionals.Xuanmiao Lyu, Marketing Influencer Manager, 3DMakerproAI applications in Additive Manufacturing (AM) impact design optimization, process monitoring, materials development, predictive maintenance, supply chain optimization, quality assurance, post-processing automation, and decision support. AI optimizes part designs for 3D printing, monitors processes in real-time, accelerates material discovery, predicts maintenance needs, enhances supply chain efficiency, automates quality control, streamlines post-processing tasks, and provides data-driven insights for better decision-making. By integrating AI across the AM workflow, industries can improve efficiency, quality, and innovation in additive manufacturing processes.Matthias Schmidt-Lehr, Managing Partner, AMPOWERAI will have an impact on material parameter development, design and simulation. Indirectly, it will certainly have an effect on every organization in areas such as marketing or software development and coding.Dr. Stefan Schulze, Director 3D Printing Materials, Lehmann & Voss & Co. KGAI will run and monitor print farms of hundreds or thousands of printers with a minimum of staff. AI will continuously monitor the printing process and the part quality in each individual printer and will give an alert or even trigger autonomously the removal of poorly printed parts to ensure a high quality level.Furthermore, AI will help operators of 3D-printers to accelerate their development along the learning curve in achieving a level of professionalism and mastering the technology seen today in injection molding. AI will do so by not only providing suggestion on how to design and print parts but by providing the reasoning behind, contributing to the continuous learning of the operator.William Alderman, Founding Partner, Alderman & CompanyWe believe one of the greatest uses of AI in AM will be in the development of exotic materials.Nick Pearce, Founder & Managing Director, Alexander Daniels GlobalAI will mainly impact AM in areas like part design, simulation and process optimisation. It could serve to optimise parameters more quickly, improve quality and repeatability of production with AM, and contribute to energy reduction and sustainability.Robert Higham, CEO & Co-Founder, Additive Manufacturing Solutions Ltd.AI as a tool to inspect and predict part performance will increase in the coming years but perhaps more importantly for me is that AI will be a method in which we can asses and quantify the relationship of geometry, materials and process for our data generated already. AI as a tool to make our data more powerful is one of the most exciting opportunities in building confidence and increasing AM industrialisation.Kristin Mulherin, Director, Additive Manufacturing Technology, HubbellAs an end-user of AM technology, my biggest concern is repeatability and reliability. AI can have a huge impact here. In 2024 we saw the emergence of some great solutions for predicting possible print failures or defects and real-time monitoring, but I think were just beginning to scratch the surface. AI will have an increasingly significant impact on AM in the coming years for this reason alone.Irma Gilbert, CEO, Autentica Industrial Platforms LtdArtificial Intelligence (AI) is poised to revolutionize Additive Manufacturing (AM) by enhancing efficiency, security, and user experiences across the following key areas:Design Automation for Machine Selection and MarketplacesAI can optimize design processes by automating the selection of the most suitable AM machines and materials for specific projects. This not only improves production efficiency but also ensures higher-quality outcomes.In digital marketplaces for 3D-printed parts, AI can match customer demands with OEM offerings, personalize recommendations, and facilitate seamless licensing transactions. For example, AI can streamline right-to-print licenses by analyzing customer preferences and manufacturing requirements, enabling more precise and tailored solutions.Quality ControlAI-powered algorithms monitor and predict defects during the printing process in real-time, significantly reducing waste and ensuring consistent quality. Machine learning models analyze sensor data to detect anomalies, enabling preemptive corrections.Post-production, AI can compare printed parts against digital twins or original models to verify adherence to specifications, thus enhancing reliability and trust in 3D-printed products.CybersecurityProtecting intellectual property (IP) is critical in AM. AI bolsters cybersecurity by detecting threats, unauthorized access, and attempts to counterfeit digital assets. AI-driven solutions, such as blockchain integration and anomaly detection algorithms, ensure secure file transfers and prevent IP theft in distributed manufacturing ecosystems.Customer ExperienceAI transforms the customer journey by leveraging predictive analytics for demand forecasting and personalized recommendations.Chatbots and virtual assistants powered by generative AI provide real-time support for inquiries, troubleshooting, and order tracking, delivering a seamless user experience. For OEMs and suppliers, AI analyzes customer feedback to refine product offerings and drive customer-centric innovation.Gene Eidelman, Cofounder, Azure Printed HomesDesign Optimization: AI can analyze data to generate highly efficient, lightweight, and structurally sound designs that would be impossible or too complex for human engineers to create alone.Production Process Automation: Machine learning algorithms can optimize printing parameters in real-time, improving print quality, reducing material usage, and minimizing errors.Predictive Maintenance: AI-driven analytics can predict when 3D printers or their components need maintenance, reducing downtime and operational costs.Material Development and Testing: AI can speed up the discovery of new materials by simulating how different formulations will behave during the printing process, significantly shortening R&D timelines.Supply Chain Optimization: AI can enhance inventory management and production planning for on-demand manufacturing, making AM an integral part of the evolving supply chain landscape.Professor Joshua Pearce, Thompson Chair in Innovation Ivey Business School and Department of Electrical & Computer Engineering, Western UniversityAI is going to be a huge help in the development of smart 3D printers that can cut down on errors while improving print speed. We will also start to see more generative AI develop models. I am most excited to see AI applied to parametric design to make developing new designs easier for everyone.Roger Uceda, CEO, aridditiveArtificial intelligence is poised to transform the 3D printing industry by democratizing design. In 2025, AI-driven tools are set to make 3D modeling accessible to non-experts, enabling anyone to create complex designs through natural language commands or intuitive sketch-based interfaces. This shift is expected to empower a broader audience, from small businesses to individual creators, to harness 3D printing without needing advanced technical skills.This democratization is likely to trigger a resurgence of desktop 3D printers, making them a central tool for creativity and innovation. Companies like Prusa and BambuLab are well-positioned to capitalize on this trend, as their user-friendly and high-performance systems align perfectly with the needs of this expanding market. This new wave of accessibility and innovation will redefine the role of 3D printing in everyday life and professional environments.Davide Ardizzoia, COO, 3ntrAI will be pervasive into design, bringing topological mapping into initial phases. Will surely then find places into part placement optimization, parameter tweaking and polymer research.Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Michael PetchMichael Petch is the editor-in-chief at 3DPI and the author of several books on 3D printing. He is a regular keynote speaker at technology conferences where he has delivered presentations such as 3D printing with graphene and ceramics and the use of technology to enhance food security. Michael is most interested in the science behind emerging technology and the accompanying economic and social implications.

Since its founding in 2019, Linares-based Meltio has sold over 500 metal 3D printers worldwide. The Spanish Direct Energy Deposition (DED) specialist also announced a 50% revenue increase in 2024, when it launched the new M600 metal 3D printer and Meltio Engine Blue integration kit.Since debuting its first 3D printer, the M450, at Formnext 2019, Meltio has expanded its global reach, with its metal 3D printers now used by customers in over 60 countries. These systems have mostly been produced at Meltios Spanish factory in Jan, which employs 120 people and exports 95% of its technology.According to Ildefonso Fuentes, Meltios CFO, the firms YoY increase in turnover is fundamentally based on clear organic growth. He explained that the decision to prioritize organic growth in the uncertain global market is particularly key to the long-term success of Meltios business.The past year has confirmed the trend in the incorporation of additive manufacturing technology as a mass manufacturing technology in industries around the world, added Meltios CEO, Angel Llavero Lopez de Villalta. Meltio is becoming worldwide thanks to our technology as a reliable alternative or complement to traditional manufacturing technologies.Meltios M600 3D printer. Image via Meltio.Meltio looks back on pivotal yearMeltio called 2024 a pivotal year marked by several significant milestones. In particular, the metal 3D printing company has pointed to the launch of its M600 3D printer. Introduced at the Additive Manufacturing Users Group (AMUG) 2024 conference last March, the DED 3D printer features a Blue Laser deposition head.The system was designed for industrial-scale manufacturing and is optimized for machine shops and other 24/7 production applications. It boasts production automation capabilities, minimizing the need for user input. In addition to fabricating original metal parts, the system can add new features to existing components and repair damaged surfaces. According to Meltio, these capabilities allow the M600 to overcome long lead times, expensive stock-keeping, and supply chain insecurities.Spanish cement company Cementos La Cruz was announced as the first customer to adopt the M600. The construction materials firm uses the system to fabricate more sustainable, 3D printed cement structures. Last year, the M600 was recognized as the top Enterprise 3D Printer of the Year (Metals) at the 2024 3D Printing Industry Awards. At the time, Villalta expressed his pride in the Meltio departments that contributed to the conception of the Meltio M600.Meltio has also highlighted the launch of Engine Blue as a key highlight of 2024. Unveiled at Formnext 2024, the 3D printing tool features blue laser technology and can be added to industrial robotic arms and vertical machining centers to unlock metal DED 3D printing. According to Meltio, the integration kit boasts a deposition rate that is 3.5 times higher than its predecessor and a 30% reduction in energy consumption.Jet engine exhaust 3D printed using Meltio Blue Engine. Image via Meltio.Additive manufacturing market conditionsFuentes noted that the economic situation within the 3D printing sector has been characterized by moderate growth over the past year. He explained that 2024 was marked by economic challenges like inflation, rising operating and production costs. However, the CFO also pointed to new growth opportunities driven by innovation and sustainability.Looking at the 3D printing hardware space, Fuentes called 2024 a turbulent year for mergers, acquisitions, and company exits. This sentiment was echoed by Villaltra, who pointed to sales declines, company bankruptcies, [and] mergers, which have shaken the global additive manufacturing market. However, he called last year a turning point where advanced technologies like 3D printing are gaining strategic weight in industries manufactring end-use parts to high standards.Amid challenging macroeconomic conditions and a more conservative environment for raising capital, Fuentes emphasized that achieving profitability has never been more important for 3D printing companies. He added that innovation remains the key driver at Meltio for the coming year. The company is developing new materials and technologies to target advanced applications and unlock improved production efficiency.Looking to the future of 3D printing, Lukas Hoppe, Meltios Head of Research and Development, predicts software developments will help exploit the full potential of laser wire deposition. On the hardware side, the Spanish company will work to enhance the performance of its M600 and Meltio Engine Blue platforms so that they remain at the forefront of innovation in industrial manufacturing.Fluctuating sales for metal 3D printersMeltios new sales milestone comes amid a precarious period for metal 3D printer sales. According to the latest CONTEXT market intelligence report, metal 3D printer sales witnessed solid performance until Q2 2024, when global sales began to fall. YoY declines were experienced in Q2 2024 and Q3 2024.In the last financial period, while binder jet sales were flat, shipments of all other metal additive manufactring technologies were down compared to the same period in 2023. DED 3D printer sales, for instance, saw sales decline by 18% compared to Q3 2023. Meanwhile, LPBF systems accounted for 74% of new industrial metal 3D printers, amid a 24% decline in shipments.Despite these falling sales, CONTEXTs VP Chris Connery pointed to some rays of hope. Notably, the Q3 report confirmed that metal 3D printing market leaders EOS, Nikon SLM Solutions, Eplus3D, and Renishaw reported YoY revenue growth. Additionally, the 3D printing laser wars trend has seen OEMs prioritize high-cost systems with more lasers, meaning fewer sales do not necessarily translate to a lower return.Amid these market conditions, metal 3D printers continued to be shipped to customers. Hangzhou-based Eplus3D recently announced that it has delivered over 100 super-meter metal LPBF 3D printers globally. Nearly 40 of these systems, which include the EP-M2050, EP-M1550, and EP-M1250 models, feature X, Y, and Z axes exceeding one meter.Who won the 2024 3D Printing Industry Awards?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows the Meltio M450. Photo via Meltio.

UK-based biotech company FabRx has announced a study exploring how pharmaceutical 3D printing can automate capsule filling in community pharmacies.Published in the International Journal of Pharmaceutics, the research examines the effectiveness of the M3DIMAKER 1 pharmaceutical 3D printer in producing minoxidil capsules, evaluating its cost, time efficiency, and safety compared to traditional manual methods. According to the team, pharmacists often rely on manual compounding, a process that demands time and carries the risk of human error. By using semi-solid extrusion (SSE) technology, the biotech companys 3D printer simplifies capsule filling, ensuring precise dosing and better consistency.M3DIMAKER 1 pharmaceutical 3D printer with the capsule holder on top of the integrated balance: (A) Full view of the capsule holder- pharmaceutical 3D printer system in a community compounding pharmacy laboratory, (B) Magnified view of the capsule holder within the printer. Image via FabRx.Advanced capsule production with 3D printingOne of the standout features of this approach is the built-in quality control system. The 3D printer, equipped with an analytical balance and pressure sensors, tracks the mass and uniformity of each capsule to meet European Pharmacopeia standards. Stability tests confirmed that capsules remained viable for up to three months under standard storage conditions.Researchers noted significant improvements in cost and efficiency. Producing 2.5 mg minoxidil capsules with the 3D printer was 35% cheaper than traditional methods, while 5 mg capsules saw a 20% cost reduction. Automating the process also cut manual labor by 55%, reducing repetitive tasks and allowing pharmacists to focus on other responsibilities. The total preparation time for treatments dropped by roughly 10%.Beyond cost and time savings, automation brought notable safety benefits. Pharmacists had less direct contact with active pharmaceutical ingredients, lowering the risk of exposure to fine powder particles. With pharma-ink extruded in a controlled environment, contamination risks were reduced, creating a safer workspace.A trial at a community pharmacy in Madrid, Spain, tested the real-world application of this method. Pharmacists used the 3D printer to prepare minoxidil capsules for nine patients. Standard operating procedures were put in place to guide pharmacy staff, and legal assessments confirmed that the process met both Spanish and European pharmaceutical compounding regulations.While 3D printed medications are still rare in clinical settings, the study suggests that this method can introduce new technology into pharmacy workflows without disrupting existing practices. Greater dosing accuracy may also prove useful for medications that require precision, such as chemotherapy and drugs with a narrow therapeutic index.As healthcare systems look toward automation and digital manufacturing, pharmaceutical 3D printing could become a scalable solution for improving efficiency, cutting costs, and ensuring medication safety. Custom formulations tailored to individual patient needs can be produced while maintaining regulatory compliance. As of now, more research will be needed to explore its wider applications and regulatory requirements in different healthcare settings.Dissolution profiles of conventional capsules and capsules prepared with a 3D printer containing 2.5 mg and 5 mg doses of minoxidil. Image via FabRx.Developments in 3D printed medicineBringing pharmaceutical 3D printing into everyday pharmacy operations opens the door for broader applications beyond minoxidil capsules. Back in 2023, Triastek, a Chinese pharmaceutical 3D printing company successfully completed its First-in-Human (FIH) study for T21, a 3D printed drug developed for moderate to severe ulcerative colitis treatment.Imaging results from the study confirm that T21 tablets achieve targeted delivery and controlled release within the colon, ensuring precise therapeutic action. Manufactured using Triasteks Melt Extrusion Deposition (MED) 3D printing technology, the tablets are designed to optimize drug administration and efficacy.Elsewhere, Max Planck Institute for Informatics researchers from Germany, and the University of California at Davis (UC Davis), introduced a new approach to 3D printed pills capable of releasing pharmaceutical drugs at controlled rates.Their study demonstrated how the dissolution speed of these pills can be influenced by their shape, which is precisely designed during the printing process. Unlike traditional drug delivery approaches such as intravenous infusion, this method offers greater control through geometric manipulation. According to the researchers, the technique could have applications beyond pharmaceuticals, including the production of catalytic structures and coarse granular fertilizers.What 3D printing trends should you watch out for in 2025?How is the future of 3D printing shaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows M3DIMAKER 1 pharmaceutical 3D printer with the capsule holder on top of the integrated balance: (A) Full view of the capsule holder- pharmaceutical 3D printer system in a community compounding pharmacy laboratory, (B) Magnified view of the capsule holder within the printer. Image via FabRx.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

Artist Raphal Emine has introduced a series of 3D printed ceramic sculptures that offer shelter to insects and small wildlife.Using WASPs 3D printers, each piece features intricate tunnels and openings designed to mimic natural structures, creating an inviting habitat for various species. Moving away from conventional enclosed public artworks, Emines pieces embrace an open and interconnected approach, allowing insects to find refuge within their intricate networks. Positioned in outdoor spaces, these sculptures evolve with the seasons, adapting to the changing environment.3D printed ecosystems for insect habitatsNamed Les Utopies Entomologiques (Entomological Utopias), the project has led to two completed installations: Utopies entomologiques I in 2023 and Utopies entomologiques II in 2024.Fabrication relied on WASPs 40100 LDM and Delta WASP 2040 Clay 3D printers alongside a Continuous Feeding System, enabling precise detailing across a range of sizes. By integrating traditional clay modeling with digital fabrication, the project explores new ways to construct ecological structures that serve a functional purpose.In Marseilles Parc Maison Blanche, another installation takes a similar approach by converting dead palm trees into supports for ceramic sculptures. The goal is to repurpose trees that have been damaged by weevil infestations, giving them a renewed function as hosts for insect-friendly structures.Each ceramic piece is strategically designed to provide nesting spaces for various species, encouraging insects to return to an environment that has suffered ecological disruptions. By introducing organic materials within the ceramic framework, the installation promotes interactions between the sculptures and local flora, further enhancing biodiversity in the park.Blending digital craftsmanship with ecological awareness, Emines work demonstrates how 3D printing can support conservation efforts. These sculptures are not just static art pieces but active participants in their surroundings.Over time, exposure to the elements and interactions with wildlife will alter their surfaces, making them a living part of the ecosystem. As the seasons change, the sculptures will weather naturally, allowing moss and other plant life to grow on them, further integrating them into their environment.Firebugs (Pyrrhocoris apterus) gather on a 3D printed ceramic insect habitat. Photo via Raphal Emine and WASP.3D printing for biodiversity and conservationIndeed, 3D printing has offered new possibilities for preserving biodiversity by creating adaptable habitats that support ecosystem restoration and wildlife conservation.A notable and recurrent example is that of coral reef preservation, with 3D printed artificial reefs deployed off the coast of Destin-Fort Walton Beach to aid marine habitat restoration. Led by the Okaloosa Coastal Resource Team and funded by a $1.26 million grant from the Florida Fish and Wildlife Conservation Commission, the project involved sinking 25 concrete modules at depths of 60 to 90 feet.Part of a broader ecological initiative using BP oil spill recovery funds, the effort saw collaboration betweenWalter Marine and 1Print, which introduced 3D concrete printing for reef construction. Reinforced with fiberglass rebar, these structures enhance marine biodiversity while providing opportunities for divers and fishers.In another development, researchers from the University of Kent and Paso Pacifico developed 3D printed decoy eggs embedded with GPS trackers to combat sea turtle egg poaching in Costa Rica. These InvestEggator devices were secretly placed among real eggs, with 25 stolen and five successfully tracking smuggling routes, the longest spanning 137 km.One led to a coastal town, providing insights into poaching networks. While some devices failed due to moisture or immediate discard, the trial demonstrated potential for law enforcement intervention. Scientist Kim Williams-Guillen, inspired by crime TV shows, devised the concept, and researchers hoped to refine the technology for broader conservation efforts, requiring further funding for improvements.What 3D printing trends should you watch out for in 2025?How is the future of 3D printing shaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows 3D printed ceramic houses for insects. Photo via Raphal Emine and WASP.

fl Optics, an Israeli company developing digital printing technology for coating optical lenses, has raised $35 million in Series A funding. The investment round was facilitated by law firm Naschitz Brandes Amir, with legal guidance from Managing Partner Tal Eliasaf and Associate Gili Aram. This funding will support the companys transition from development to large-scale production and commercialization.The funding round was led by key players in the ophthalmic industry, including a strategic minority investment from MEI Systems, a global leader in lens-edging machinery and automation solutions. The partnership highlights fl Optics potential to disrupt traditional coating methods with digital printing technology.The capital will be used to accelerate product development, scale up production, and support customer installations. According to Jonathan Jaglom, Chairman and CEO of fl Optics, the investment marks the companys transition from the development phase to full-scale commercialization.fl Optics team. Photo via fl Optics.We found an affinity with the disruptive, innovative approach of fl Optics, said Stefano Sonzogni, President of MEI Systems. At MEI, we always think outside the box to revolutionize processes and meet our customers needs, and we see that same passion driving fl Optics.Jaglom emphasized that the funding will allow fl Optics to establish a significant market presence, stating: This funding round not only validates the market potential of our technology but also aligns us with partners who share our vision for innovation and excellence. We are grateful for the trust investors have placed in us.The companys first commercial product, the Visin100, will make its debut at Mido 2025, the worlds largest international eyewear exhibition.3D Printing in Eyewear ProductionAdvancements in additive manufacturing are altering traditional eyewear production methods. In 2023, GENERA launched its G1/F1 system for in-store 3D printing of glasses frames, allowing opticians to manufacture frames on demand. The system integrates Henkels Digital Acetate material, which offers high transparency and vibrant coloration. The platform, branded as Mission Eyewear, is designed to automate the production workflow, reducing manual labor and enabling direct customization at the point of sale.Elsewhere, Spectra Additive, a company using DLP technology from Austrian manufacturer GENERA, began full-scale 3D printed eyewear production in December 2023. The firm partnered with material specialist Henkel to develop eyewear frames with high precision and repeatability, utilizing the Loctite 3D MED9851 resin. Their target production capacity for 2025 is 30,000 frames, reflecting an increasing shift toward additive manufacturing in the eyewear sector.Complete 3D printed glasses frame with GENERAs DLP technology. Photo via Spectra+.Ready to discover who won the 20243D Printing Industry Awards?What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured image shows the fl Optics team. Photo via fl Optics.