There has been a new update to the ongoing Stratasys v. Bambu Lab patent infringement lawsuit.  Both parties have agreed to consolidate the lead and member cases (2:24-CV-00644-JRG and 2:24-CV-00645-JRG) into a single case under Case No. 2:25-cv-00465-JRG.  Industrial 3D printing OEM Stratasys filed the request late last month. According to an official court document, Shenzhen-based Bambu Lab did not oppose the motion. Stratasys argued that this non-opposition amounted to the defendants waiving their right to challenge the request under U.S. patent law 35 U.S.C. § 299(a). On June 2, the U.S. District Court for the Eastern District of Texas, Marshall Division, ordered Bambu Lab to confirm in writing whether it agreed to the proposed case consolidation. The court took this step out of an “abundance of caution” to ensure both parties consented to the procedure before moving forward. Bambu Lab submitted its response on June 12, agreeing to the consolidation. The company, along with co-defendants Shenzhen Tuozhu Technology Co., Ltd., Shanghai Lunkuo Technology Co., Ltd., and Tuozhu Technology Limited, waived its rights under 35 U.S.C. § 299(a). The court will now decide whether to merge the cases. This followed U.S. District Judge Rodney Gilstrap’s decision last month to deny Bambu Lab’s motion to dismiss the lawsuits.  The Chinese desktop 3D printer manufacturer filed the motion in February 2025, arguing the cases were invalid because its US-based subsidiary, Bambu Lab USA, was not named in the original litigation. However, it agreed that the lawsuit could continue in the Austin division of the Western District of Texas, where a parallel case was filed last year.  Judge Gilstrap denied the motion, ruling that the cases properly target the named defendants. He concluded that Bambu Lab USA isn’t essential to the dispute, and that any misnaming should be addressed in summary judgment, not dismissal.        A Stratasys Fortus 450mc (left) and a Bambu Lab X1C (right). Image by 3D Printing industry. Another twist in the Stratasys v. Bambu Lab lawsuit  Stratasys filed the two lawsuits against Bambu Lab in the Eastern District of Texas, Marshall Division, in August 2024. The company claims that Bambu Lab’s X1C, X1E, P1S, P1P, A1, and A1 mini 3D printers violate ten of its patents. These patents cover common 3D printing features, including purge towers, heated build plates, tool head force detection, and networking capabilities. Stratasys has requested a jury trial. It is seeking a ruling that Bambu Lab infringed its patents, along with financial damages and an injunction to stop Bambu from selling the allegedly infringing 3D printers. Last October, Stratasys dropped charges against two of the originally named defendants in the dispute. Court documents showed that Beijing Tiertime Technology Co., Ltd. and Beijing Yinhua Laser Rapid Prototyping and Mould Technology Co., Ltd were removed. Both defendants represent the company Tiertime, China’s first 3D printer manufacturer. The District Court accepted the dismissal, with all claims dropped without prejudice. It’s unclear why Stratasys named Beijing-based Tiertime as a defendant in the first place, given the lack of an obvious connection to Bambu Lab.  Tiertime and Stratasys have a history of legal disputes over patent issues. In 2013, Stratasys sued Afinia, Tiertime’s U.S. distributor and partner, for patent infringement. Afinia responded by suing uCRobotics, the Chinese distributor of MakerBot 3D printers, also alleging patent violations. Stratasys acquired MakerBot in June 2013. The company later merged with Ultimaker in 2022. In February 2025, Bambu Lab filed a motion to dismiss the original lawsuits. The company argued that Stratasys’ claims, focused on the sale, importation, and distribution of 3D printers in the United States, do not apply to the Shenzhen-based parent company. Bambu Lab contended that the allegations concern its American subsidiary, Bambu Lab USA, which was not named in the complaint filed in the Eastern District of Texas. Bambu Lab filed a motion to dismiss, claiming the case is invalid under Federal Rule of Civil Procedure 19. It argued that any party considered a “primary participant” in the allegations must be included as a defendant.    The court denied the motion on May 29, 2025. In the ruling, Judge Gilstrap explained that Stratasys’ allegations focus on the actions of the named defendants, not Bambu Lab USA. As a result, the official court document called Bambu Lab’s argument “unavailing.” Additionally, the Judge stated that, since Bambu Lab USA and Bambu Lab are both owned by Shenzhen Tuozhu, “the interest of these two entities align,” meaning the original cases are valid.   In the official court document, Judge Gilstrap emphasized that Stratasys can win or lose the lawsuits based solely on the actions of the current defendants, regardless of Bambu Lab USA’s involvement. He added that any potential risk to Bambu Lab USA’s business is too vague or hypothetical to justify making it a required party. Finally, the court noted that even if Stratasys named the wrong defendant, this does not justify dismissal under Rule 12(b)(7). Instead, the judge stated it would be more appropriate for the defendants to raise that argument in a motion for summary judgment. The Bambu Lab X1C 3D printer. Image via Bambu Lab. 3D printing patent battles  The 3D printing industry has seen its fair share of patent infringement disputes over recent months. In May 2025, 3D printer hotend developer Slice Engineering reached an agreement with Creality over a patent non-infringement lawsuit.  The Chinese 3D printer OEM filed the lawsuit in July 2024 in the U.S. District Court for the Northern District of Florida, Gainesville Division. The company claimed that Slice Engineering had falsely accused it of infringing two hotend patents, U.S. Patent Nos. 10,875,244 and 11,660,810. These cover mechanical and thermal features of Slice’s Mosquito 3D printer hotend. Creality requested a jury trial and sought a ruling confirming it had not infringed either patent. Court documents show that Slice Engineering filed a countersuit in December 2024. The Gainesville-based company maintained that Creaility “has infringed and continues to infringe” on both patents. In the filing, the company also denied allegations that it had harassed Creality’s partners, distributors, and customers, and claimed that Creality had refused to negotiate a resolution.   The Creality v. Slice Engineering lawsuit has since been dropped following a mutual resolution. Court documents show that both parties have permanently dismissed all claims and counterclaims, agreeing to cover their own legal fees and costs.  In other news, large-format resin 3D printer manufacturer Intrepid Automation sued 3D Systems over alleged patent infringement. The lawsuit, filed in February 2025, accused 3D Systems of using patented technology in its PSLA 270 industrial resin 3D printer. The filing called the PSLA 270 a “blatant knock off” of Intrepid’s DLP multi-projection “Range” 3D printer.   San Diego-based Intrepid Automation called this alleged infringement the “latest chapter of 3DS’s brazen, anticompetitive scheme to drive a smaller competitor with more advanced technology out of the marketplace.” The lawsuit also accused 3D Systems of corporate espionage, claiming one of its employees stole confidential trade secrets that were later used to develop the PSLA 270 printer. 3D Systems denied the allegations and filed a motion to dismiss the case. The company called the lawsuit “a desperate attempt” by Intrepid to distract from its own alleged theft of 3D Systems’ trade secrets. 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 Stratasys Fortus 450mc (left) and a Bambu Lab X1C (right). Image by 3D Printing industry.

Global sportswear leader Nike is reportedly preparing to release the Air Max 1000 Oatmeal, its first fully 3D printed sneaker, with a launch tentatively scheduled for Summer 2025. While Nike has yet to confirm an official release date, industry sources suggest the debut may occur sometime between June and August. The retail price is expected to be approximately $210. This model marks a step in Nike’s exploration of additive manufacturing (AM), enabled through a collaboration with Zellerfeld, a German startup known for its work in fully 3D printed footwear. Building Buzz Online The “Oatmeal” colorway—a neutral blend of soft beige tones—has already attracted attention on social platforms like TikTok, Instagram, and X. In April, content creator Janelle C. Shuttlesworth described the shoes as “light as air” in a video preview. Sneaker-focused accounts such as JustFreshKicks and TikTok user @shoehefner5 have also offered early walkthroughs. Among fans, the nickname “Foamy Oat” has started to catch on. Nike’s 3D printed Air Max 1000 Oatmeal. Photo via Janelle C. Shuttlesworth. Before generating buzz online, the sneaker made a public appearance at ComplexCon Las Vegas in November 2024. There, its laceless, sculptural silhouette and smooth, seamless texture stood out—merging futuristic design with signature Air Max elements, such as the visible heel air unit. Reimagining the Air Max Legacy Drawing inspiration from the original Air Max 1 (1987), the Air Max 1000 retains the iconic air cushion in the heel while reinventing the rest of the structure using 3D printing. The shoe’s upper and outsole are formed as a single, continuous piece, produced from ZellerFoam, a proprietary flexible material developed by Zellerfeld. Zellerfeld’s fused filament fabrication (FFF) process enables varied material densities throughout the shoe—resulting in a firm, supportive sole paired with a lightweight, breathable upper. The laceless, slip-on design prioritizes ease of wear while reinforcing a sleek, minimalist aesthetic. Nike’s Chief Innovation Officer, John Hoke, emphasized the broader impact of the design, noting that the Air Max 1000 “opens up new creative possibilities” and achieves levels of precision and contouring not possible with traditional footwear manufacturing. He also pointed to the sustainability benefits of AM, which produces minimal waste by fabricating only the necessary components. Expansion of 3D Printed Footwear Technology The Air Max 1000 joins a growing lineup of 3D printed footwear innovations from major brands. Gucci, the Italian luxury brand known for blending traditional craftsmanship with modern techniques, unveiled several Cub3d sneakers as part of its Spring Summer 2025 (SS25) collection. The brand developed Demetra, a material made from at least 70% plant-based ingredients, including viscose, wood pulp, and bio-based polyurethane. The bi-material sole combines an EVA-filled interior for cushioning and a TPU exterior, featuring an Interlocking G pattern that creates a 3D effect. Elsewhere, Syntilay, a footwear company combining artificial intelligence with 3D printing, launched a range of custom-fit slides. These slides are designed using AI-generated 3D models, starting with sketch-based concepts that are refined through AI platforms and then transformed into digital 3D designs. The company offers sizing adjustments based on smartphone foot scans, which are integrated into the manufacturing process. Join our Additive Manufacturing Advantage (AMAA) event on July 10th, where AM leaders from Aerospace, Space, and Defense come together to share mission-critical insights. Online and free to attend.Secure your spot now. Who won the2024 3D Printing Industry Awards? Subscribe to the 3D Printing Industry newsletterto keep up with the latest 3D printing news. You can also follow us onLinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content. Featured image shows Nike’s 3D printed Air Max 1000 Oatmeal. Photo via Janelle C. Shuttlesworth. Paloma Duran Paloma Duran holds a BA in International Relations and an MA in Journalism. Specializing in writing, podcasting, and content and event creation, she works across politics, energy, mining, and technology. With a passion for global trends, Paloma is particularly interested in the impact of technology like 3D printing on shaping our future.

Researchers from the US-based University of Massachusetts Amherst (UMass), in collaboration with the Massachusetts Institute of Technology (MIT) Department of Mechanical Engineering, have applied cold spray to repair the deteriorating “Brown Bridge” in Great Barrington, built in 1949. The project marks the first known use of this method on bridge infrastructure and aims to evaluate its effectiveness as a faster, more cost-effective, and less disruptive alternative to conventional repair techniques. “Now that we’ve completed this proof-of-concept repair, we see a clear path to a solution that is much faster, less costly, easier, and less invasive,” said Simos Gerasimidis, associate professor of civil and environmental engineering at the University of Massachusetts Amherst. “To our knowledge, this is a first. Of course, there is some R&D that needs to be developed, but this is a huge milestone to that,” he added. The pilot project is also a collaboration with the Massachusetts Department of Transportation (MassDOT), the Massachusetts Technology Collaborative (MassTech), the U.S. Department of Transportation, and the Federal Highway Administration. It was supported by the Massachusetts Manufacturing Innovation Initiative, which provided essential equipment for the demonstration. Members of the UMass Amherst and MIT Department of Mechanical Engineering research team, led by Simos Gerasimidis (left, standing). Photo via UMass Amherst. Tackling America’s Bridge Crisis with Cold Spray Technology Nearly half of the bridges across the United States are in “fair” condition, while 6.8% are classified as “poor,” according to the 2025 Report Card for America’s Infrastructure. In Massachusetts, about 9% of the state’s 5,295 bridges are considered structurally deficient. The costs of restoring this infrastructure are projected to exceed $190 billion—well beyond current funding levels.  The cold spray method consists of propelling metal powder particles at high velocity onto the beam’s surface. Successive applications build up additional layers, helping restore its thickness and structural integrity. This method has successfully been used to repair large structures such as submarines, airplanes, and ships, but this marks the first instance of its application to a bridge. One of cold spray’s key advantages is its ability to be deployed with minimal traffic disruption.  “Every time you do repairs on a bridge you have to block traffic, you have to make traffic controls for substantial amounts of time,” explained Gerasimidis. “This will allow us to [apply the technique] on this actual bridge while cars are going [across].” To enhance precision, the research team integrated 3D LiDAR scanning technology into the process. Unlike visual inspections, which can be subjective and time-consuming, LiDAR creates high-resolution digital models that pinpoint areas of corrosion. This allows teams to develop targeted repair plans and deposit materials only where needed—reducing waste and potentially extending a bridge’s lifespan. Next steps: Testing Cold-Sprayed Repairs The bridge is scheduled for demolition in the coming years. When that happens, researchers will retrieve the repaired sections for further analysis. They plan to assess the durability, corrosion resistance, and mechanical performance of the cold-sprayed steel in real-world conditions, comparing it to results from laboratory tests. “This is a tremendous collaboration where cutting-edge technology is brought to address a critical need for infrastructure in the commonwealth and across the United States,” said John Hart, Class of 1922 Professor in the Department of Mechanical Engineering at MIT. “I think we’re just at the beginning of a digital transformation of bridge inspection, repair and maintenance, among many other important use cases.” 3D Printing for Infrastructure Repairs Beyond cold spray techniques, other innovative 3D printing methods are emerging to address construction repair challenges. For example, researchers at University College London (UCL) have developed an asphalt 3D printer specifically designed to repair road cracks and potholes. “The material properties of 3D printed asphalt are tunable, and combined with the flexibility and efficiency of the printing platform, this technique offers a compelling new design approach to the maintenance of infrastructure,” the UCL team explained. Similarly, in 2018, Cintec, a Wales-based international structural engineering firm, contributed to restoring the historic Government building known as the Red House in the Republic of Trinidad and Tobago. This project, managed by Cintec’s North American branch, marked the first use of additive manufacturing within sacrificial structures. It also featured the installation of what are claimed to be the longest reinforcement anchors ever inserted into a structure—measuring an impressive 36.52 meters. Join our Additive Manufacturing Advantage (AMAA) event on July 10th, where AM leaders from Aerospace, Space, and Defense come together to share mission-critical insights. Online and free to attend.Secure your spot now. Who won the2024 3D Printing Industry Awards? Subscribe to the 3D Printing Industry newsletterto keep up with the latest 3D printing news. You can also follow us onLinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content. Featured image shows members of the UMass Amherst and MIT Department of Mechanical Engineering research team, led by Simos Gerasimidis (left, standing). Photo via UMass Amherst.

Additive Manufacturing UK (AMUK)’s first Members Forum of 2025 was held at Siemens’ UK headquarters in South Manchester earlier this year. The event featured presentations from AMUK members and offered attendees a chance to network and share insights.  Ahead of the day-long meetup, 3D Printing Industry caught up with Joshua Dugdale, Head of AMUK, to learn more about the current state of additive manufacturing and the future of 3D printing in Britain.  AMUK is the United Kingdom’s primary 3D printing trade organization. Established in 2014, it operates within the Manufacturing Technologies Association (MTA) cluster. Attendees at this year’s first meetup spanned the UK’s entire 3D printing ecosystem. Highlights included discussion on precious materials from Cookson Industrial, simulation software from Siemens, digital thread solutions from Kaizen PLM, and 3D printing services provided by ARRK.  With a background in mechanical engineering, Dugdale is “responsible for everything and anything AMUK does as an organization.” According to the Loughborough University alumnus, who is also Head of Technology and Skills at the MTA, AMUK’s core mission is to “create an environment in the UK where additive manufacturing can thrive.” He elaborated on how his organization is working to increase the commercial success of its members within the “struggling” global manufacturing environment. Dugdale shared his perspective on the key challenges facing 3D printing in the UK. He pointed to a “tough” operating environment hampered by global financial challenges, which is delaying investments.  Despite this, AMUK’s leader remains optimistic about the sector’s long-term potential, highlighting the UK’s success in R&D and annual 3D printing intellectual property (IP) output. Dugdale emphasized the value of 3D printing for UK defense and supply chain resilience, arguing that “defense will lead the way” in 3D printing innovation.  Looking ahead, Dugdale called on the UK Government to create a unified 3D printing roadmap to replace its “disjointed” approach to policy and funding. He also shared AMUK’s strategy for 2025 and beyond, emphasizing a focus on eductaion, supply chain visibility, and standards. Ultimately, the AMUK figurehead shared a positive outlook on the future of 3D printing in the UK. He envisions a new wave of innovation that will see more British startups and university spinouts emerging over the next five years.          Siemens’ Manchester HQ hosted the first AMUK Members Forum of 2025. Photo by 3D Printing Industry. What is the current state of additive manufacturing in the UK? According to Dugdale, the 3D printing industry is experiencing a challenging period, driven largely by global economic pressures. “I wouldn’t describe it as underperforming, I’d describe it as flat,” Dugdale said. “The manufacturing sector as a whole is facing significant challenges, and additive manufacturing is no exception.” He pointed to increased competition, a cautious investment climate, and the reluctance of businesses to adopt new technologies due to the economic uncertainty.  Dugdale specifically highlighted the increase in the UK’s National Insurance contribution (NIC) rate for employers, which rose from 13.8% to 15% on April 6, 2025. He noted that many British companies postponed investment decisions ahead of the announcement, reflecting growing caution within the UK manufacturing sector. “With additive manufacturing, people need to be willing to take risks,” added Dugdale. “People are holding off at the moment because the current climate doesn’t favor risk.”  Dugdale remains optimistic about the sector’s long-term potential, arguing that the UK continues to excel in academia and R&D. However, for Dugdale, commercializing that research is where the country must improve before it can stand out on the world stage. This becomes especially clear when compared to countries in North America and Asia, which receive significantly greater financial support. “We’re never going to compete with the US and China, because they have so much more money behind them,” he explained. In a European context, Dugdale believes the UK “is doing quite well.” However, Britain remains below Spain in terms of financial backing and technology adoption. “Spain has a much more mature industry,” Dugdale explained. “Their AM association has been going for 10 years, and it’s clear that their industry is more cohesive and further along. It’s a level of professionalism we can learn from.” While the Iberian country faces similar challenges in standards, supply chain, and visibility, it benefits from a level of cohesion that sets it apart from many other European countries. Dugdale pointed to the Formnext trade show as a clear example of this disparity. He expects the Spanish pavilion to span around 200 square meters and feature ten companies at this year’s event, a “massive” difference compared to the UK’s 36 square meters last year. AMUK’s presence could grow to around 70 square meters at Formnext 2025, but this still lags far behind. Dugdale attributes this gap to government support. “They get more funding. This makes it a lot more attractive for companies to come because there’s less risk for them,” he explained.   Josh Dugdale speaking at the AMUK Members Forum in Manchester. Photo by 3D Printing Industry. 3D printing for UK Defense  As global security concerns grow, the UK government has intensified efforts to bolster its defense capabilities. In this context, 3D printing is emerging as a key enabler. Earlier this year, the Ministry of Defence (MoD) released its first Defence Advanced Manufacturing Strategy, outlining a plan to “embrace 3D printing,” with additive manufacturing expected to play a pivotal role in the UK’s future military operations.  Dugdale identified two key advantages of additive manufacturing for defense: supply chain resilience and frontline production. For the former, he stressed the importance of building localized supply chains to reduce lead times and eliminate dependence on overseas shipments. This capability is crucial for ensuring that military platforms, whether on land, at sea, or in the air, remain operational.  3D printing near the front lines offers advantages for conducting quick repairs and maintaining warfighting capabilities in the field. “If a tank needs to get back off the battlefield, you can print a widget or bracket that’ll hold for just five miles,” Dugdale explained. “It’s not about perfect engineering; it’s about getting the vehicle home.”  The British Army has already adopted containerized 3D printers to test additive manufacturing near the front lines. Last year, British troops deployed metal and polymer 3D printers during Exercise Steadfast Defender, NATO’s largest military exercise since the Cold War. Dubbed Project Bokkr, the additive manufacturing capabilities included XSPEE3D cold spray 3D printer from Australian firm SPEE3D.     Elsewhere in 2024, the British Army participated in Additive Manufacturing Village 2024, a military showcase organized by the European Defence Agency. During the event, UK personnel 3D printed 133 functional parts, including 20 made from metal. They also developed technical data packs (TDPs) for 70 different 3D printable spare parts. The aim was to equip Ukrainian troops with the capability to 3D print military equipment directly at the point of need. Dugdale believes success in the UK defense sector will help drive wider adoption of 3D printing. “Defense will lead the way,” he said, suggesting that military users will build the knowledge base necessary for broader civilian adoption. This could also spur innovation in materials science, an area Dugdale expects to see significant advancements in the coming years.     A British Army operator checks a part 3D printed on SPEE3D’s XSPEE3D Cold Spray 3D printer. Photo via the British Army. Advocating for a “unified industrial strategy” Despite promising growth in defence, Dugdale identified major hurdles that still hinder the widespread adoption of additive manufacturing (AM) in the UK.  A key challenge lies in the significant knowledge gap surrounding the various types of AM and their unique advantages. This gap, he noted, discourages professionals familiar with traditional manufacturing methods like milling and turning from embracing 3D printing. “FDM is not the same as WAAM,” added Dugdale. “Trying to explain that in a very nice, coherent story is not always easy.” Dugdale also raised concerns about the industry’s fragmented nature, especially when it comes to software compatibility and the lack of interoperability between 3D printing systems. “The software is often closed, and different machines don’t always communicate well with each other. That can create fear about locking into the wrong ecosystem too early,” he explained.  For Dugdale, these barriers can only be overcome with a clear industrial strategy for additive manufacturing. He believes the UK Government should develop a unified strategy that defines a clear roadmap for development. This, Dugdale argued, would enable industry players to align their efforts and investments.  The UK has invested over £500 million in AM-related projects over the past decade. However, Dugdale explained that fragmented funding has limited its impact. Instead, the AMUK Chief argues that the UK Government’s strategy should recognize AM as one of “several key enabling technologies,” alongside machine tooling, metrology, and other critical manufacturing tools.  He believes this unified approach could significantly boost the UK’s productivity and fully integrate 3D printing into the wider industrial landscape. “Companies will align themselves with the roadmap, allowing them to grow and mature at the same rate,” Dugdale added. “This will help us to make smarter decisions about how we fund and where we fund.”    AMUK’s roadmap and the future of 3D printing in the UK    When forecasting 3D printing market performance, Dugdale and his team track five key industries: automotive, aerospace, medical, metal goods, and chemical processes. According to Dugdale, these industries are the primary users of machine tools, which makes them crucial indicators of market health. AMUK also relies on 3D printing industry surveys to gauge confidence, helping them to spot trends even when granular data is scarce. By comparing sector performance with survey-based confidence indicators, AMUK builds insights into the future market trajectory. The strong performance of sectors like aerospace and healthcare, which depend heavily on 3D printing, reinforces Dugdale’s confidence in the long-term potential of additive manufacturing. Looking ahead to the second half of 2025, AMUK plans to focus on three primary challenges: supply chain visibility, skills development, and standards. Dugdale explains that these issues remain central to the maturation of the UK’s AM ecosystem. Education will play a key role in these efforts.  AMUK is already running several additive manufacturing upskilling initiatives in schools and universities to build the next generation of 3D printing pioneers. These include pilot projects that introduce 3D printing to Key Stage 3 students (aged 11) and AM university courses that are tailored to industry needs.  In the longer term, Dugdale suggests AMUK could evolve to focus more on addressing specific industry challenges, such as net-zero emissions or automotive light-weighting. This would involve creating specialized working groups that focus on how 3D printing can address specific pressing issues.  Interestingly, Dugdale revealed that AMUK’s success in advancing the UK’s 3D printing industry could eventually lead to the organization being dissolved and reabsorbed into the MTA. This outcome, he explained, would signal that “additive manufacturing has really matured” and is now seen as an integral part of the broader manufacturing ecosystem, rather than a niche technology. Ultimately, Dugdale is optimistic for the future of 3D printing in the UK. He acknowledged that AMUK is still “trying to play catch-up for the last 100 years of machine tool technology.” However, additive manufacturing innovations are set to accelerate. “There’s a lot of exciting research happening in universities, and we need to find ways to help these initiatives gain the funding and visibility they need,” Dugdale urged. As the technology continues to grow, Dugdale believes additive manufacturing will gradually lose its niche status and become a standard tool for manufacturers. “In ten years, we could see a generation of workers who grew up with 3D printers at home,” he told me. “For them, it will just be another technology to use in the workplace, not something to be amazed by.”  With this future in mind, Dugdale’s vision for 3D printing is one of broad adoption, supported by clear strategy and policy, as the technology continues to evolve and integrate into UK industry.  Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. 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Researchers from the Department of Mechanical Engineering at Virginia Tech have introduced a continuous fiber reinforcement (CFR) deposition tool designed for multi-axis 3D printing, significantly enhancing mechanical performance in composite structures. Led by Kieran D. Beaumont, Joseph R. Kubalak, and Christopher B. Williams, and published in Springer Nature Link, the study demonstrates an 820% improvement in maximum load capacity compared to conventional planar short carbon fiber (SCF) 3D printing methods. This tool integrates three key functions: reliable fiber cutting and re-feeding, in situ fiber volume fraction control, and a slender collision volume to support complex multi-axis toolpaths. The newly developed deposition tool addresses critical challenges in CFR additive manufacturing. It is capable of cutting and re-feeding continuous fibers during travel movements, a function required to create complex geometries without material tearing or print failure. In situ control of fiber volume fraction is also achieved by adjusting the polymer extrusion rate. A slender geometry minimizes collisions between the tool and the printed part during multi-axis movements. The researchers designed the tool to co-extrude a thermoplastic polymer matrix with a continuous carbon fiber (CCF) towpreg. This approach allowed reliable fiber re-feeding after each cut and enabled printing with variable fiber content within a single part. The tool’s slender collision volume supports increased range of motion for the robotic arm used in the experiments, allowing alignment of fibers with three-dimensional load paths in complex structures. The six Degree-of-Freedom Robotic Arm printing a multi-axis geometry from a CFR polymer composite. Photo via Springer Nature Link. Mechanical Testing Confirms Load-Bearing Improvements Mechanical tests evaluated the impact of continuous fiber reinforcement on polylactic acid (PLA) parts. In tensile tests, samples reinforced with continuous carbon fibers achieved a tensile strength of 190.76 MPa and a tensile modulus of 9.98 GPa in the fiber direction. These values compare to 60.31 MPa and 3.01 GPa for neat PLA, and 56.92 MPa and 4.30 GPa for parts containing short carbon fibers. Additional tests assessed intra-layer and inter-layer performance, revealing that the continuous fiber–reinforced material had reduced mechanical properties in these orientations. Compared to neat PLA, intra-layer tensile strength and modulus dropped by 66% and 63%, respectively, and inter-layer strength and modulus decreased by 86% and 60%. Researchers printed curved tensile bar geometries using three methods to evaluate performance in parts with three-dimensional load paths: planar short carbon fiber–reinforced PLA, multi-axis short fiber–reinforced samples, and multi-axis continuous fiber–reinforced composites. The multi-axis short fiber–reinforced parts showed a 41.6% increase in maximum load compared to their planar counterparts. Meanwhile, multi-axis continuous fiber–reinforced parts absorbed loads 8.2 times higher than the planar short fiber–reinforced specimens. Scanning electron microscopy (SEM) images of fracture surfaces revealed fiber pull-out and limited fiber-matrix bonding, particularly in samples with continuous fibers. Schematic illustration of common continuous fiber reinforcement–material extrusion (CFR-MEX) modalities: in situ impregnation, towpreg extrusion, and co-extrusion with towpreg. Photo via Springer Nature Link. To verify the tool’s fiber cutting and re-feeding capability, the researchers printed a 100 × 150 × 3 mm rectangular plaque that required 426 cutting and re-feeding operations across six layers. The deposition tool achieved a 100% success rate, demonstrating reliable cutting and re-feeding without fiber clogging. This reliability is critical for manufacturing complex structures that require frequent travel movements between deposition paths. In situ fiber volume fraction control was validated through printing a rectangular prism sample with varying polymer feed rates, road widths, and layer heights. The fiber volume fractions achieved in different sections of the part were 6.51%, 8.00%, and 9.86%, as measured by cross-sectional microscopy and image analysis. Although lower than some literature reports, the researchers attributed this to the specific combination of tool geometry, polymer-fiber interaction time, and print speed. The tool uses Anisoprint’s CCF towpreg, a pre-impregnated continuous carbon fiber product with a fiber volume fraction of 57% and a diameter of 0.35 mm. 3DXTECH’s black PLA and SCF-PLA filaments were selected to ensure consistent matrix properties and avoid the influence of pigment variations on mechanical testing. The experiments were conducted using an ABB IRB 4600–40/2.55 robotic arm equipped with a tool changer for switching between the CFR-MEX deposition tool and a standard MEX tool with an elongated nozzle for planar prints. Deposition Tool CAD and Assembly. Photo via Springer Nature Link. Context Within Existing Research and Future Directions Continuous fiber reinforcement in additive manufacturing has previously demonstrated significant improvements in part performance, with some studies reporting tensile strengths of up to 650 MPa for PLA composites reinforced with continuous carbon fibers. However, traditional three-axis printing methods restrict fiber orientation to planar directions, limiting these gains to within the XY-plane. Multi-axis 3D printing approaches have demonstrated improved load-bearing capacity in short-fiber reinforced parts. For example, multi-axis printed samples have shown failure loads several times higher than planar-printed counterparts in pressure cap and curved geometry applications. Virginia Tech’s tool integrates multiple functionalities that previous tools in literature could not achieve simultaneously. It combines a polymer feeder based on a dual drive extruder, a fiber cutter and re-feeder assembly, and a co-extrusion hotend with adjustable interaction time for fiber-polymer bonding. A needle-like geometry and external pneumatic cooling pipes reduce the risk of collision with the printed part during multi-axis reorientation. Measured collision volume angles were 56.2° for the full tool and 41.6° for the hotend assembly. Load-extension performance graphs for curved tensile bars. Photo via Springer Nature Link. Despite these advances, the researchers identified challenges related to weak bonding between the fiber and the polymer matrix. SEM images showed limited impregnation of the polymer into the fiber towpreg, with the fiber-matrix interface remaining a key area for future work. The study highlights that optimizing fiber tow sizing and improving the fiber-polymer interaction time during printing could enhance inter-layer and intra-layer performance. The results also suggest that advanced toolpath planning algorithms could further leverage the tool’s ability to align fiber deposition along three-dimensional load paths, improving mechanical performance in functional parts. The publication in Springer Nature Link documents the full design, validation experiments, and mechanical characterization of the CFR-MEX tool. The work adds to a growing body of research on multi-axis additive manufacturing, particularly in combining continuous fiber reinforcement with complex geometries. Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. Ready to discover who won the 20243D Printing Industry Awards? Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights. Featured photo shows the six Degree-of-Freedom Robotic Arm printing a multi-axis geometry. Photo via Springer Nature Link. Anyer Tenorio Lara Anyer Tenorio Lara is an emerging tech journalist passionate about uncovering the latest advances in technology and innovation. With a sharp eye for detail and a talent for storytelling, Anyer has quickly made a name for himself in the tech community. Anyer's articles aim to make complex subjects accessible and engaging for a broad audience. In addition to his writing, Anyer enjoys participating in industry events and discussions, eager to learn and share knowledge in the dynamic world of technology.

Researchers from the National University of Singapore (NUS) have developed a 3D printed, self-powered mechanoluminescent (ML) photonic skin designed for communication and safety monitoring in underwater environments. The stretchable device emits light in response to mechanical deformation, requires no external power source, and remains functional under conditions such as high salinity and extreme temperatures. The findings were published in Advanced Materials by Xiaolu Sun, Shaohua Ling, Zhihang Qin, Jinrun Zhou, Quangang Shi, Zhuangjian Liu, and Yu Jun Tan. The research was conducted at NUS and Singapore’s Agency for Science, Technology and Research (A*STAR). Schematic of the 3D printed mechanoluminescent photonic skin showing fabrication steps and light emission under deformation. Image via Sun et al., Advanced Materials. 3D printing stretchable light-emitting skins with auxetic geometry The photonic skin was produced using a 3D printing method called direct-ink-writing (DIW), which involves extruding a specially formulated ink through a fine nozzle to build up complex structures layer by layer. In this case, the ink was made by mixing tiny particles of zinc sulfide doped with copper (ZnS:Cu), a material that glows when stretched, with a flexible silicone rubber. These particles serve as the active ingredient that lights up when the material is deformed, while the silicone acts as a soft, stretchable support structure. To make the device more adaptable to movement and curved surfaces, like human skin or underwater equipment, the researchers printed it using auxetic designs. Auxetic structures have a rare mechanical property known as a negative Poisson’s ratio. Unlike most materials, which become thinner when stretched, auxetic designs expand laterally under tension. This makes them ideal for conforming to curved or irregular surfaces, such as joints, flexible robots, or underwater gear, without wrinkling or detaching. Encapsulating the printed skin in a clear silicone layer further improves performance by distributing mechanical stress evenly. This prevents localized tearing and ensures that the light emission remains bright and uniform, even after 10,000 cycles of stretching and relaxing. In previous stretchable light-emitting devices, uneven stress often led to dimming, flickering, or early material failure. Mechanical and optical performance of encapsulated photonic skin across 10,000 stretch cycles. Image via Sun et al., Advanced Materials. Underwater signaling, robotics, and gas leak detection The team demonstrated multiple applications for the photonic skin. When integrated into wearable gloves, the skin enabled light-based Morse code communication through simple finger gestures. Bending one or more fingers activated the mechanoluminescence, emitting visible flashes that corresponded to messages such as “UP,” “OK,” or “SOS.” The system remained fully functional when submerged in cold water (~7°C), simulating deep-sea conditions. In a separate test, the skin was applied to a gas tank mock-up to monitor for leaks. A pinhole defect was covered with the printed skin and sealed using stretchable tape. When pressurized air escaped through the leak, the localized mechanical force caused a bright cyan glow at the exact leak site, offering a passive, electronics-free alternative to conventional gas sensors. To test performance on soft and mobile platforms, the researchers also mounted the photonic skin onto a robotic fish. As the robot swam through water tanks at different temperatures (24°C, 50°C, and 7°C), the skin continued to light up reliably, demonstrating its resilience and utility for marine robotics. Comparison of printed photonic skin structures with different geometries and their conformability to complex surfaces. Image via Sun et al., Advanced Materials. Toward electronics-free underwater communication While LEDs and optical fibers are widely used in underwater lighting systems, their dependence on rigid form factors and external power makes them unsuitable for dynamic, flexible applications. In contrast, the stretchable ML photonic skin developed by NUS researchers provides a self-powered, adaptable alternative for diver signaling, robotic inspection, and leak detection, potentially transforming the toolkit for underwater communication and safety systems. Future directions include enhanced sensory integration and robotic applications, as the team continues exploring robust photonic systems for extreme environments. Photonic skin integrated into gloves for Morse code signaling and applied to robotic fish and gas tanks for underwater safety monitoring. Image via Sun et al., Advanced Materials. The rise of 3D printed multifunctional materials The development of the photonic skin reflects a broader trend in additive manufacturing toward multifunctional materials, structures that serve more than a structural role. Researchers are increasingly using multimaterial 3D printing to embed sensing, actuation, and signaling functions directly into devices. For example, recent work by SUSTech and City University of Hong Kong on thick-panel origami structures showed how multimaterial printing can enable large, foldable systems with high strength and motion control. These and other advances, including conductive FDM processes and Lithoz’s multimaterial ceramic tools, mark a shift toward printing entire systems. The NUS photonic skin fits squarely within this movement, combining mechanical adaptability, environmental durability, and real-time optical output into a single printable form. Read the full article in Advanced Materials Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news. You can also follow us onLinkedIn and subscribe to the 3D Printing Industry YouTube channel to access more exclusive content. At 3DPI, our mission is to deliver high-quality journalism, technical insight, and industry intelligence to professionals across the AM ecosystem.Help us shape the future of 3D printing industry news with our2025 reader survey. Featured image shows a schematic of the 3D printed mechanoluminescent photonic skin showing fabrication steps and light emission under deformation. Image via Sun et al., Advanced Materials.

Conflux Technology, an Australian company specializing in heat transfer solutions and additive manufacturing, has announced a collaboration with Italian hypercar manufacturer Pagani to address thermal management challenges in the Pagani Utopia’s transmission. The Utopia, Pagani’s latest hypercar, uses a 6-liter twin-turbo V12 engine designed by Mercedes-AMG. Its powertrain integrates a custom seven-speed transmission developed by Xtrac, available in both automated and manual configurations, to deliver the high levels of control and responsiveness required in extreme driving conditions. The Australian-based firm developed a cartridge heat exchanger specifically for the Utopia’s transmission oil system to improve heat rejection. According to the company, this solution achieves a 30% increase in heat rejection compared to the previous heat exchanger design. This enhancement is critical to maintain optimal thermal performance during high-load operations and ensures the vehicle meets global emissions standards, including those in California. Pagani’s Utopia hypercar, powered by a 6-liter twin-turbo V12 engine. Photo via Conflux Technology. Pagani subjected the Utopia’s transmission system to extensive testing, including track and road validation as well as thermal shock trials. These tests confirmed the durability and thermal resilience of the new heat exchanger under demanding operational conditions, aligning with the vehicle’s performance requirements. Michael Fuller, Founder and CEO of Conflux Technology, said: “Our advanced heat exchangers are designed to enable new levels of effectiveness, perfectly complementing the engineering craftsmanship that Pagani is celebrated for. This collaboration showcases the synergy of precision, innovation, and excellence.” Francesco Perini, Head of the Technical Department at Pagani, emphasized: “Conflux’s advanced heat transfer technology empowers the Pagani Utopia to achieve superior heat rejection ensuring optimal thermal balance, even in severe driving conditions. In our relentless pursuit of perfection, every detail matters. Conflux’s cartridge heat exchangers are a testament to precision and innovation, playing a vital role in ensuring that the Utopia can be enjoyed for a romantic drive on the French Riviera as well as on the most demanding tracks.” Oliver Nixon, Head of High Performance Automotive at Xtrac, stated: “The innovation of Conflux’s technology has allowed Xtrac to continue to push the boundaries of transmission performance, whilst maintaining the lightweight, motorsport derived ethos of our transmission solutions.” Conflux Technology’s additive-manufactured cartridge heat exchangers. Photo via Conflux Technology. Conflux is developing its Conflux Production Systems (CPS) to scale the production of its heat exchangers, supported by an AUD 11 million Series B funding round. The company’s technology is applied across multiple sectors, including aerospace, motorsports, high-powered industrial equipment, and defense, where effective thermal management is essential. The cartridge design leverages additive manufacturing to produce complex geometries that enhance heat transfer while reducing weight, supporting the requirements of high-performance automotive applications. Xtrac, headquartered in Berkshire, UK, with additional facilities in Indiana and North Carolina, specializes in engineering transmission and driveline systems for both motorsport and automotive sectors. Engine bay featuring Xtrac’s seven-speed gearbox. Photo via Conflux Technology. Additive Manufacturing in High-Performance Automotive Design Bentley Motors recent limited-run Batur grand tourer, The Black Rose, integrates additive manufacturing into its design through 18-karat recycled rose gold components. Developed by the Mulliner division in collaboration with precious metal supplier Cooksongold, the project uses up to 210 grams of printed gold in elements such as the Drive Mode Selector, air vent controls, and steering wheel insert. These components are hallmarked in Birmingham’s Jewellery Quarter, with some also bearing the hallmark commemorating Queen Elizabeth II’s Platinum Jubilee. Bentley’s investment in additive manufacturing capacity since 2022 amounts to £3 million. This focus on additive manufacturing extends to high-performance vehicle engineering, as seen in McLaren Automotive’s W1 hypercar. The W1 incorporates titanium 3D printing in the production of front uprights and wishbones for its suspension system, contributing to significant weight savings and enhanced dynamic performance. McLaren reports that the W1 achieves a vehicle weight of 1,399kg, enabling a power-to-weight ratio of 911PS/tonne and supporting acceleration from 0 to 200km/h in 5.8 seconds. Central to this development is the company’s collaboration with Divergent Technologies, whose DAPS platform supports rapid design iteration and manufacturing flexibility.s. Front view of the McLaren W1 hypercar. Image via McLaren. Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. Ready to discover who won the 2024 3D Printing Industry Awards? Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights. Featured photo shows Pagani’s Utopia hypercar, powered by a 6-liter twin-turbo V12 engine. Photo via Conflux Technology. Anyer Tenorio Lara Anyer Tenorio Lara is an emerging tech journalist passionate about uncovering the latest advances in technology and innovation. With a sharp eye for detail and a talent for storytelling, Anyer has quickly made a name for himself in the tech community. Anyer's articles aim to make complex subjects accessible and engaging for a broad audience. In addition to his writing, Anyer enjoys participating in industry events and discussions, eager to learn and share knowledge in the dynamic world of technology.

The Digital Manufacturing and Cybersecurity Institute (MxD) has released its Strategic Investment Plan (SIP) for 2025-2027, presenting a detailed roadmap to bolster the competitiveness, resilience, and cybersecurity of U.S. manufacturing.  Shaped by insights from manufacturers, technology providers, academic institutions, and government partners, the plan lays out a targeted investment strategy in digital engineering, factory modernization, supply chain resilience, and workforce development.  Published on March 19, 2025, the SIP identifies core areas for MxD’s focus over the next three years: digital engineering and design, future factory systems, supply chain visibility, and cybersecurity integration. These initiatives aim to address persistent challenges within the industrial base, particularly among small and medium-sized manufacturers (SMMs) that often lack the resources needed to adopt and scale digital manufacturing solutions. “We will continue to prioritize projects and proposals designed to meet the evolving needs of the industrial base, relying on your insights and involvement throughout. Our collaborative approach has proven to be effective during MxD’s first decade and continues to be the model driving this SIP and MxD forward,” Berardino Baratta, CEO at MxD. Illustration of the product lifecycle and how the flow of data represents a complex interconnected web among all aspects. Image via MxD. Data lifecycle framework and investment focus At the center of the SIP is a technical framework called the data lifecycle. This framework maps the flow of data across the various stages of a product’s lifecycle, from development and manufacturing to deployment and support. MxD underscores the importance of seamless data movement and high-fidelity data collection, which are vital for unlocking capabilities such as predictive maintenance, quality control, and secure information sharing throughout supply chains. MxD’s data lifecycle approach has already been applied in 189 research, cybersecurity, and workforce development projects totaling $415 million in public-private investments. One example, Project 22-06-01, titled “Proactive Worker Safety for Industry 4.0 Using AI,” employed artificial intelligence (AI) and Internet of Things (IoT) sensors to reduce worker fatigue, addressing a $136 billion annual challenge for US employers. For the 2025-2027 period, MxD plans to prioritize projects that promote technology adoption across supply chains, supported by new playbooks and guides to help manufacturers modernize, close digital gaps, and apply lessons from pilot programs. This approach aims to foster coordinated, sector-wide adoption. Another central pillar of the SIP is interoperability and data standards. MxD is working on a Machine-to-X Data Standards Playbook to consolidate and harmonize data standards used by manufacturers. This effort addresses the challenge of fragmented data formats and standards across different systems, which can hinder consistent data flows and semantic interoperability. To support digital engineering and design, MxD is updating model-based definition assessments to address the shortcomings of current evaluations and provide clearer guidance for manufacturers aiming to improve digital maturity. These updates will bolster MxD’s broader goal of enhancing collaboration and data sharing across product lifecycles, enabling better designs, improved performance, and reduced costs. Future factory development is another key emphasis of the SIP. MxD’s projects in this area aim to build digital environments that support real-time process optimization, data-driven decision-making, and production lines that can adapt quickly to disruptions and new customer demands. Initiatives around digital twins, 5G/6G integration, and cybersecurity best practices will help shape these future factories. In terms of supply chain resilience, the SIP outlines plans for new risk assessment tools and visibility platforms. These tools will rely on secure data-sharing practices and advanced analytics to reduce disruptions and improve the agility of domestic manufacturing in a volatile global landscape. Cybersecurity is also a core focus of the SIP, reflecting MxD’s role as the National Center for Cybersecurity in Manufacturing. With manufacturing identified as the most targeted sector for cyberattacks in recent years, MxD’s cybersecurity projects aim to enhance protections for both operational technology (OT) and information technology (IT) environments.  Two engineers walking through a manufacturing facility. Photo via MxD. The Digital Education, Resilience, and Innovation for Supply Chain (DERISC) initiative, carried out with the Defense Logistics Agency (DLA), is an example of how MxD is equipping U.S. manufacturers with the tools and protocols needed to secure their supply chains against digital threats. Workforce training and capability roadmaps On the workforce development front, MxD’s Virtual Training Center (VTC) offers around 20,000 courses tailored to meet the evolving needs of manufacturers.  These courses include advanced role-based training programs in data analytics, cybersecurity, and extended reality applications. As an affordable and scalable learning platform, the VTC aims to close the gap in workforce training for SMMs that often lack access to comprehensive learning management systems. MxD’s training programs, such as the Curriculum and Pathways Integrating Technology and Learning Program (CAPITAL) and Cybersecurity for Manufacturing Operational Technology (CyMOT) initiatives, are designed to prepare workers for digital manufacturing roles while also supporting national defense efforts by delivering specialized cybersecurity training for supply chain participants. The SIP identifies these workforce initiatives as critical, noting that 1.9 million manufacturing jobs could remain unfilled by 2033 without targeted upskilling efforts. Beyond individual projects, the SIP features an Appendix of Capability Advancement Roadmaps. These roadmaps chart technical progress across multiple domains, emphasizing that data standards, architecture, and interoperability are essential to enabling future-ready manufacturing.  For instance, roadmaps for digital twin deployment and supply chain visibility outline clear timelines and performance milestones, providing a transparent view of how MxD plans to scale its impact. MxD’s structured approach and technical framework are designed to help manufacturers adopt secure, data-driven practices that align with broader economic and defense objectives. As digital manufacturing influences operational practices and product standards, the SIP provides a framework that supports a more adaptable and resilient US manufacturing sector. Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. 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, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows illustration of the product lifecycle and how the flow of data represents a complex interconnected web among all aspects. Image via MxD. Ada Shaikhnag With 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.

3D printer manufacturer Bambu Lab has issued a new update after an early fix was withdrawn. Termed a critical calibration bug, the company has acted swiftly to deliver new code to its many users. The Shenzhen-based company has now released firmware version V01.01.02.07 for its H2D 3D printer through its Public Beta Program. Rolled out on May 23, this update introduces a comprehensive set of new features, performance enhancements, and critical bug fixes designed to elevate print quality, expand hardware compatibility, and offer users greater control. The release builds on feedback gathered from earlier beta phases. The Bambu Lab H2D Laser Full Combo in a workshop. Image via Bambu Lab. Features and Improvements Firmware V01.01.02.07 adds native support for the CyberBrick time-lapse kit. It also expands the H2D’s onboard AI failure detection system, now giving users the ability to individually toggle detection functions for nozzle clumping, spaghetti printing, air printing, and purge chute pile-ups from the printer’s interface. Hardware compatibility has been further extended. The AMS 2 Pro and AMS HT systems now support RFID-based automatic matching of drying parameters and can perform drying operations without rotating spools. Additionally, the Laser & Cut module can now initiate tasks directly from USB drive files, improving workflow support. Performance updates include improved foreign object detection on the smooth PEI plate, better regulation of heatbed temperatures, enhanced first-layer quality, more reliable chamber temperature checks before printing begins, and improved accuracy of laser module flame detection. The update also enhances the accuracy of nozzle clumping and nozzle camera dirty detection, while optimizing the pre-purging strategy. A collision issue between the nozzle flow blocker and nozzle wiper—previously triggered during flow dynamics calibration—has been resolved. Calibration reliability for the liveview camera has also improved, and issues with pre-extrusion lines sticking to prints during layer transitions have been addressed. Bambu Lab H2D Launch. Image via Bambu Lab. However, two known issues remain in this beta release: detection of filament PTFE tube detachment is currently disabled, and users cannot adjust heatbed temperature via the Bambu Handy app. The latter is expected to be fixed in a future app update. This version replaces V01.01.02.04, which was briefly released on May 20 before being withdrawn due to a critical calibration bug. That earlier version caused the right nozzle to crash into the wiper during left-nozzle calibration, damaging the printer. The firmware also temporarily disabled filament detachment detection. Bambu Lab quickly pulled the update and advised users to revert to the previous stable firmware while working on a corrected release—now realized in version V01.01.02.07. Accessing the Firmware To access the beta firmware, users can opt into the Public Beta Program through the Bambu Handy app by navigating to the “Me” section and selecting “Beta Firmware Program.” Once enrolled, the update will be rolled out gradually. Participants can leave the program at any time and revert to the most recent stable firmware version. Bambu Lab recommends updating Bambu Studio Presets before installing the firmware to ensure full compatibility. Full technical documentation and the official changelog are available on Bambu Lab’s website. Bambu Lab Hardware Line: H2D and Beyond The new firmware update applies to the H2D 3D printer, Bambu Lab’s flagship desktop manufacturing system unveiled in March 2025. Designed for professional users, the H2D offers the company’s largest build volume to date—350 x 320 x 325 mm—and includes two new AMS systems with integrated filament drying. Dual-nozzle extrusion and servo-driven precision deliver high accuracy, while a 350°C hotend and 65°C heated chamber allow reliable printing with high-performance, fiber-reinforced materials. With a toolhead speed of up to 1000 mm/s and acceleration of 20,000 mm/s², the H2D is built for productivity without compromising quality. The Bambu Lab H2D’s digital cutter. Image via Bambu Lab. Bambu Lab’s broader portfolio also includes the X1E, released in 2023 as an enterprise-grade upgrade to its X1 series. Developed with professional and engineering applications in mind, the X1E features LAN-only connectivity for secure, offline operation, enhanced air filtration, and precise thermal regulation. An increased maximum nozzle temperature expands its material compatibility, making it suitable for demanding industrial applications. At its core, the X1E builds on the proven performance of the X1 Carbon, extending the system’s capabilities for use in sensitive or regulated environments. Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. Who won the 2024 3D Printing Industry Awards? Subscribe to the3D 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 Bambu Lab H2D Launch. Image via Bambu Lab. Paloma Duran Paloma Duran holds a BA in International Relations and an MA in Journalism. Specializing in writing, podcasting, and content and event creation, she works across politics, energy, mining, and technology. With a passion for global trends, Paloma is particularly interested in the impact of technology like 3D printing on shaping our future.

Researchers at the University of Texas at Austin have developed a novel resin system for multicolor digital light processing (DLP) 3D printing that enables rapid fabrication of freestanding and non-assembly structures using dissolvable supports. The work, led by Zachariah A. Page and published in ACS Central Science, combines UV- and visible-light-responsive chemistries to produce materials with distinct solubility profiles, significantly streamlining post-processing. Current DLP workflows are often limited by the need for manually removed support structures, especially when fabricating components with overhangs or internal joints. These limitations constrain automation and increase production time and cost. To overcome this, the team designed wavelength-selective photopolymer resins that form either an insoluble thermoset or a readily dissolvable thermoplastic, depending on the light color used during printing. In practical terms, this allows supports to be printed in one material and rapidly dissolved using ethyl acetate, an environmentally friendly solvent, without affecting the primary structure. The supports dissolve in under 10 minutes at room temperature, eliminating the need for time-consuming sanding or cutting. Illustration comparing traditional DLP 3D printing with manual support removal (A) and the new multicolor DLP process with dissolvable supports (B). Image via University of Texas at Austin. The research was supported by the U.S. Army Research Office, the National Science Foundation, and the Robert A. Welch Foundation. The authors also acknowledge collaboration with MonoPrinter and Lawrence Livermore National Laboratory. High-resolution multimaterial printing The research showcases how multicolor DLP can serve as a precise multimaterial platform, achieving sub-100 μm feature resolution with layer heights as low as 50 μm. By tuning the photoinitiator and photoacid systems to respond selectively to ultraviolet (365 nm), violet (405 nm), or blue (460 nm) light, the team spatially controlled polymer network formation in a single vat. This enabled the production of complex, freestanding structures such as chainmail, hooks with unsupported overhangs, and fully enclosed joints, which traditionally require extensive post-processing or multi-step assembly. The supports, printed in a visible-light-cured thermoplastic, demonstrated sufficient mechanical integrity during the build, with tensile moduli around 160–200 MPa. Yet, upon immersion in ethyl acetate, they dissolved within 10 minutes, leaving the UV-cured thermoset structure intact. Surface profilometry confirmed that including a single interface layer of the dissolvable material between the support and the final object significantly improved surface finish, lowering roughness to under 5 μm without polishing. Computed tomography scans validated geometric fidelity, with dimensional deviations from CAD files as low as 126 μm, reinforcing the method’s capability for high-precision, solvent-cleared multimaterial printing. Comparison of dissolvable and traditional supports in DLP 3D printing. (A) Disk printed with soluble supports using violet light, with rapid dissolution in ethyl acetate. (B) Gravimetric analysis showing selective mass loss. (C) Mechanical properties of support and structural materials. (D) Manual support removal steps. (E) Surface roughness comparison across methods. (F) High-resolution test print demonstrating feature fidelity. Image via University of Texas at Austin. Towards scalable automation This work marks a significant step toward automated vat photopolymerization workflows. By removing manual support removal and achieving clean surface finishes with minimal roughness, the method could benefit applications in medical devices, robotics, and consumer products. The authors suggest that future work may involve refining resin formulations to enhance performance and print speed, possibly incorporating new reactive diluents and opaquing agents for improved resolution. Examples of printed freestanding and non-assembly structures, including a retainer, hook with overhangs, interlocked chains, and revolute joints, before and after dissolvable support removal. Image via University of Texas at Austin. Dissolvable materials as post-processing solutions Dissolvable supports have been a focal point in additive manufacturing, particularly for enhancing the efficiency of post-processing. In Fused Deposition Modeling (FDM), materials like Stratasys’ SR-30 have been effectively removed using specialized cleaning agents such as Oryx Additive‘s SRC1, which dissolves supports at twice the speed of traditional solutions. For resin-based printing, systems like Xioneer‘s Vortex EZ employ heat and fluid agitation to streamline the removal of soluble supports . In metal additive manufacturing, innovations have led to the development of chemical processes that selectively dissolve support structures without compromising the integrity of the main part . These advancements underscore the industry’s commitment to reducing manual intervention and improving the overall efficiency of 3D printing workflows. Read the full article in ACS Publications. Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news. You can also follow us onLinkedIn and subscribe to the 3D Printing Industry YouTube channel to access more exclusive content. At 3DPI, our mission is to deliver high-quality journalism, technical insight, and industry intelligence to professionals across the AM ecosystem.Help us shape the future of 3D printing industry news with our2025 reader survey. Featured image shows: Hook geometry printed using multicolor DLP with dissolvable supports. Image via University of Texas at Austin.

Molecular Rebar Design, a nanomaterials company based in Austin, Texas, has patented a new additive manufacturing (AM) composition that utilizes oxidized discrete carbon nanotubes (CNTs) with bonded dispersing agents to enhance 3D printing resins. The patent, published under US20210237509A1, outlines methods to improve resin properties for applications such as vat photopolymerization, sintering, and thermoplastic fusion. The inventors, Clive P. Bosnyak, Kurt W. Swogger, Steven Lowder, and Olga Ivanova, propose formulations that improve electrical conductivity, thermal stability, and mechanical strength, while overcoming dispersion challenges common with CNTs in composite materials. Image shows a schematic diagram of functionalized carbon nanotubes. Image via Molecular Rebar Design. Functionalized CNTs for additive manufacturing At the core of the invention is the chemical functionalization of CNTs with dispersing agents bonded to their sidewalls, enabling higher aspect ratios and more homogeneous dispersions. These dispersions integrate into UV-curable acrylates, thermoplastics, and elastomers, yielding improved green strength, sinterability, and faster cure rates. The patent emphasizes the benefit of using bimodal or trimodal distributions of CNT diameters (single-, double-, or multi-wall) to tune material performance. Additional fillers such as carbon black, silica, and metallic powders can also be incorporated for applications ranging from electronic encapsulation to impact-resistant parts. Experimental validation To validate the invention, the applicants oxidized carbon nanotubes using nitric acid and covalently bonded them with polyether dispersing agents such as Jeffamine M2005. These modified CNTs were incorporated into photopolymer resin formulations. In tensile testing, specimens produced with the dispersions demonstrated enhanced mechanical performance, with yield strengths exceeding 50 MPa and Young’s modulus values above 2.8 GPa. Impact strength improved by up to 90% in certain formulations compared to control samples without CNTs. These performance gains suggest suitability for applications demanding high strength-to-weight ratios, such as aerospace, electronics, and structural components. Nanotube innovations in AM Carbon nanotubes (CNTs) have long been explored for additive manufacturing (AM) due to their exceptional mechanical and electrical properties. However, challenges such as poor dispersion and inconsistent aspect ratios have hindered their widespread adoption in AM processes. Recent advancements aim to overcome these barriers by integrating oxidation and dispersion techniques into scalable production methods. For instance, researchers at Rice University have developed a novel acid-based solvent that prevents the common “spaghetti effect” of CNTs tangling together. This innovation simplifies the processing of CNTs, potentially enabling their scale-up for industrial 3D printing applications. Similarly, a research team led by the University of Glasgow has created a 3D printable CNT-based plastic material capable of sensing its own structural health. This material, inspired by natural porous structures, offers enhanced toughness and strength, with potential applications in medicine, prosthetics, automotive, and aerospace design. Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news. You can also follow us onLinkedIn and subscribe to the 3D Printing Industry YouTube channel to access more exclusive content. At 3DPI, our mission is to deliver high-quality journalism, technical insight, and industry intelligence to professionals across the AM ecosystem.Help us shape the future of 3D printing industry news with our2025 reader survey. Feature image shows schematic diagram of functionalized carbon nanotubes. Image via Molecular Rebar Design.

Shenzhen-based 3D printer manufacturer Elegoo has introduced a new RFID Ecosystem for its upcoming printer line, including the upcoming Elegoo Saturn 4 Ultra. This system integrates RFID-tagged resin bottles, an Elegoo-designed scanner, and cloud-connected print profiles. Elegoo has opened a public feedback solicitation on its website and GitHub page to refine the implementation and encourage community input. The company is currently testing several use cases, such as automatic profile loading, material usage tracking, and batch traceability. Elegoo says these features aim to streamline workflow, reduce errors, and assist in quality assurance. However, in a GitHub post, the company emphasized that its RFID system is optional and will not lock users into proprietary materials. An open approach to a closed-loop trend? The Elegoo RFID Ecosystem enters a broader conversation in the additive manufacturing (AM) industry regarding material-locking strategies and proprietary ecosystems. As discussed in a recent 3D Printing Industry analysis, the proliferation of closed systems has triggered renewed debate about interoperability, user autonomy, and long-term value for manufacturers and end-users alike. Elegoo appears to be taking a middle-ground approach: providing automation and traceability features via RFID while maintaining support for third-party materials. In the Elegoo RFID Tag Guide, developers are encouraged to create and test custom tags, with detailed instructions and example code provided to the open-source community. Developer-centric rollout The Elegoo Saturn 4 Ultra, which serves as the first testbed for the RFID system, uses a dedicated RFID reader to retrieve data from tags affixed to resin bottles. These tags store encoded information such as resin name, type, batch number, and print profile metadata. The printer’s firmware can automatically sync this information with cloud-hosted slicer settings for optimal prints. According to the company, future updates may include compatibility with other Elegoo printers and additional features like usage history logging, tamper detection, and resin validation for regulatory compliance. Color scheme guide possibly used for tag classification or UI indication in Elegoo’s RFID material system. Image via Elegoo. A call for collaboration In its official blog post, Elegoo invited users, developers, and material manufacturers to contribute feedback and propose new applications. The company has not yet announced a formal launch date for the ecosystem or its associated hardware. Elegoo, known for its budget-friendly resin and FDM printers, has been expanding its R&D efforts in recent years. With the RFID ecosystem, it now joins other AM firms experimenting with embedded metadata and smart materials integration to support traceability, security, and ease of use. Interoperability and user autonomy The debate about open vs closed ecosystems has increasingly intensified in additive manufacturing discussions. For example, Bambu Lab’s controversial firmware update that introduced new authentication protocols, sparking concerns about third-party compatibility and user autonomy. Subsequent coverage highlighted pushback from the open-source community, including Orca Slicer developers, who rejected integration with Bambu Connect over transparency and access concerns. These cases underscore how interoperability is not only a technical issue, but a strategic and ideological one shaping the future of the AM sector.RFID in 3D printing While RFID integration is more common in logistics and supply chain management, researchers and companies are beginning to explore its potential in 3D printing. Scientists at Swinburne University developed biosensing RFID tags using 3D printed hybrid liquids, enabling applications in health diagnostics and environmental sensing. Meanwhile, materials firm Supernova unveiled a new resin cartridge system embedded with RFID to improve compatibility and process control in high-viscosity 3D printing platforms. These developments suggest that RFID could play a growing role in material authentication, traceability, and automated workflow management within additive manufacturing ecosystems.Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news. You can also follow us onLinkedIn and subscribe to the 3D Printing Industry YouTube channel to access more exclusive content. At 3DPI, our mission is to deliver high-quality journalism, technical insight, and industry intelligence to professionals across the AM ecosystem.Help us shape the future of 3D printing industry news with our2025 reader survey. Featured image shows Elegoo RFID system displayed on a resin bottle, designed to communicate encoded material data to the printer. Image via Elegoo.

CADENAS GmbH, a software company based in Augsburg, Germany, has joined the KEYENCE Group. The acquisition is intended to advance the development of 3Dfindit, CADENAS’ engineering platform, and enhance its digital catalog capabilities for global users. Founded in 1992, CADENAS operates a platform that connects around 10 million engineers and designers with suppliers of 3D CAD components. The company has steadily expanded over three decades, providing catalog-based solutions that support digital part integration across multiple manufacturing sectors. This strategic shift comes after more than 30 years of independent growth. KEYENCE, a Japanese corporation specializing in automation and inspection equipment, has reported consistent annual growth of 10% for the past 25 years. As of March 2024, it ranked among the five largest companies in Japan by market capitalization. With operations in 46 countries and a customer base of 350,000 businesses, the group’s acquisition of CADENAS is positioned to extend its reach in digital engineering infrastructure. According to the Augsburg-based firm, existing customer relationships will remain unchanged. It stated that its team will stay intact, with ongoing independent development of its software. “We will remain a neutral, reliable partner for manufacturers and companies of all kinds, regardless of industry,” reads the company statement. It also clarified that customer data will continue to be handled internally. The new arrangement is expected to contribute to KEYENCE’s long-term objective of expanding its technology offering and support systems. While the engineering platform will continue operating under its current structure, it will now complement the broader industrial automation ecosystem of its new parent company. Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. CADENAS becomes part of the KEYENCE Group. Image via CADENAS GmbH. Strategic acquisitions reshape digital manufacturing landscape In March, United Performance Metals (UPM) acquired Fabrisonic, an Ohio-based manufacturer known for its ultrasonic additive manufacturing (UAM) technology. Following the acquisition, Fabrisonic was integrated into UPM’s processing network, which includes sites in Connecticut, Ohio, and California. The supplier of specialty metals stated that Fabrisonic’s technology and expertise would enhance its ability to develop advanced materials and expand its manufacturing capabilities. Fabrisonic General Manager Jason Riley credited the company’s engineers as key to its progress and said the acquisition would support the next phase of growth. A month later, Nano Dimension completed its $116 million acquisition of Markforged Holding Corporation, a U.S.-based manufacturer of FDM 3D printers. The transaction followed a period of internal restructuring at Nano Dimension, including leadership changes and the resolution of legal disputes related to other merger agreements. Markforged, which reported annual revenues exceeding $85 million, brings an installed base of 15,000 systems, along with capabilities in metal and composite manufacturing and AI-driven production software. As part of the agreement, Markforged’s CFO, Assaf Zipori, was appointed Chief Financial Officer of Nano Dimension. Ready to discover who won the 20243D Printing Industry Awards? Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights. Featured image shows CADENAS becomes part of the KEYENCE Group. Image via CADENAS GmbH. Anyer Tenorio Lara Anyer Tenorio Lara is an emerging tech journalist passionate about uncovering the latest advances in technology and innovation. With a sharp eye for detail and a talent for storytelling, Anyer has quickly made a name for himself in the tech community. Anyer's articles aim to make complex subjects accessible and engaging for a broad audience. In addition to his writing, Anyer enjoys participating in industry events and discussions, eager to learn and share knowledge in the dynamic world of technology.

Harris Tweed, a Scottish textile brand, is working with the National Manufacturing Institute Scotland (NMIS) to integrate 3D printing technology into its traditional loom systems. The integration seeks to improve part accessibility and support the long-term sustainability of its weaving operations in the Outer Hebrides. Kelly McDonald, operations manager at The Harris Tweed Authority, noted that while the organization takes pride in its craftsmanship and tradition, it also recognizes that innovation is essential to maintaining the strength and resilience of the industry. “Working with NMIS is a significant step forward in future-proofing the looms critical to the production of Harris Tweed. With the ability to replace parts quickly, easily, and affordably, our weavers can focus on what they do best without worrying about delays. This not only safeguards the future of our fabric but also supports the livelihoods of the island community who dedicate their skills to preserving the craft.” Harris Tweed Fabric. Photo via Harris Tweed. The Traditional Harris Tweed Process and New Innovations To address these issues, The Harris Tweed Loom Spares Co. partnered with NMIS—operated by the University of Strathclyde and part of the High Value Manufacturing Catapult—to develop 3D printed loom parts. The collaboration focuses on improving access to essential components and reducing dependence on long supply chains. At NMIS’s Digital Factory in Renfrewshire, engineers applied reconditioning techniques and tested durable materials to create high-quality parts. One key loom assembly, initially comprising seven separate pieces, was redesigned into three components made from strong composite material. This new version reduces costs by 99% and can be printed locally using a desktop 3D printer in approximately two hours. “When a vital part of the loom breaks, it can halt production for weeks, which is incredibly frustrating. Finding a way to keep the loom running smoothly is essential, and it’s been great to be one of the first to try out the new 3D printed assembly. The ability to get what we need, when we need it, will make a huge difference, as it means we can minimise downtime and focus on our work without unnecessary interruptions.” Old and new assemblies side by side. Photo via Harris Tweed. Ongoing Development and Future Goals Andrew Bjonnes, R&D engineer at NMIS Digital Factory, stated: “This project really showcases how modern manufacturing can boost traditional industries and help preserve valuable heritage skills. With additive manufacturing, we’re promoting self-sufficiency and giving weavers a smart, cost-effective, and user-friendly way to keep their looms up and running. It has been an incredibly rewarding project, making a tangible difference and allowing weavers to concentrate on their craft instead of worrying about equipment failures.” Andrew Bjonnes with new assembly. Photo via Harris Tweed. 3D Printing’s Impact on Fashion Design  3D fashion printing is expanding the range of possibilities for designers, providing new tools and techniques that enhance durability, sustainability, and creativity in the industry. In February, the New York Embroidery Studio (NYES), a surface design studio specializing in embroidered designs and textile embellishments for high-profile events like the MET Gala, integrated the Stratasys J850 TechStyle, marketed as the world’s first additive manufacturing system designed for direct printing on textiles. This addition enables the studio to create detailed, tactile designs, improve workflow efficiency, and reduce material waste. “The J850 TechStyle is an extraordinary addition to our capabilities. Our clients are thrilled by the possibilities this technology opens up—from high-end fashion to VIP and entertainment projects. Combining the precision of 3D printing with our expertise in embroidery allows us to push boundaries like never before,” said Michelle Feinberg, Owner and Creative Director of NYES. Elsewhere, Coperni introduced its gel bag at Disneyland Paris, created using Rapid Liquid Printing (RLP), a technique developed by MIT’s Self-Assembly Lab. RLP fabricates objects directly within a gel suspension, enabling the creation of soft, stretchable, and durable designs. Made from recyclable platinum-cured silicone, the bag highlights how advanced manufacturing techniques can seamlessly blend with fashion design while maintaining a strong focus on sustainability. Take the 3DPIReader Survey — shape the future of AM reporting in under 5 minutes. Who won the 2024 3D Printing Industry Awards? Subscribe to the3D 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 Andrew Bjonnes with new assembly. Photo via Harris Tweed.

In this edition of SLICED, the 3D Printing Industry news digest, we compile the latest developments across the additive manufacturing (AM) sector, including equipment-sharing partnerships, market expansions in Europe and Mexico, and new standards working groups. Today’s edition features reseller appointments, research consortium launches, large-format platform integrations, dental appliance automation, and calls for conference speakers. Read on for updates from AM 4 AM, Meltio, One Click Metal, Axtra3D, Nikon SLM Solutions, Formnext 2025, and more. Emerging partnerships from AM 4 AM, and Meltio Kicking off with partnerships, Luxembourg’s materials R&D firm AM 4 AM has partnered with Stockholm aluminum powder supplier Gränges Powder Metallurgy (GPM), relocating the Swedish supplier’s materials characterization park to AM 4 AM’s facility. Under the agreement, AM 4 AM will operate GPM’s particle size analyzers, thermal testers, and mechanical-testing rigs to accelerate development cycles and strengthen quality control across both companies’ product lines. AM 4 AM Co-founder Maxime Delmée noted that access to GPM’s instrumentation will enable faster iteration and more data-driven decision-making. Highlighting benefits, GPM Managing Director Peter Vikner explained that relocating the equipment to AM 4 AM addressed both firms’ R&D requirements while leveraging AM 4 AM’s operational capabilities. Moving on, Spanish wire-laser metal 3D printer manufacturer Meltio has announced partnerships with Monterrey-based service provider Alar, and academic institution  Tecnológico de Monterrey.With this move, Alar will integrate the award-winning M600 industrial wire-laser 3D printer into its production lines, while the institution has acquired a Meltio M450 for academic training and industry collaboration.  Additionally, the Spanish manufacturer has also announced additive manufacturing integrator Sitres Latam as its official distributor. Meltio’s wire-feed deposition process, which supports stainless steel, titanium, Inconel, and copper, offers mechanical properties on par with conventionally manufactured parts while reducing waste and emissions. “This alliance with Sitres, Alar, and Tecnológico de Monterrey is fundamental to promoting real and functional metal 3D printing solutions in Mexico,” said Alar CEO Andrea Alarcón. Meltio partners with Alar, SITRES, and Tecnológico de Monterrey to expand metal 3D printing capabilities in Mexico. Photo via Meltio. One Click Metal and Axtra3D Appoint New Resellers in Iberia Turning to resellers and distribution, German metal 3D printing systems developer One Click Metal has expanded into Portugal through a collaboration with Lisbon’s industrial additive manufacturing services provider 3D Ever. The agreement gives local businesses direct access to One Click Metal’s cartridge-based powder handling systems and Lab Module for rapid material changes, alongside region-specific training and post-installation support. Founded in 2017, 3D Ever operates a multi-technology showroom—covering covering stereolithography (SLA), selective laser sintering (SLS), fused filament fabrication (FFF), and direct metal laser sintering (DMLS)—and hosts open-house events and technical workshops to integrate 3D printing into customer workflows. “Portugal is a dynamic market for additive manufacturing,” said One Click Metal’s Global Sales Director Martin Heller, “and 3D Ever’s deep industry knowledge makes them the ideal partner.” Meanwhile, Milan-based photopolymer 3D printer innovator Axtra3D has named Spain and Portugal’s Maquinser S.A. as its professional reseller for Hi-Speed SLA systems. Maquinser will showcase the Lumia X1 platform combining Hybrid PhotoSynthesis and TruLayer technologies at three major industry events through June: the International Machine-Tool Fair (EMAF) in Porto, Portugal; the Subcontratación Industrial & Addit3D expo in Bilbao, Spain; and the MindTECH manufacturing technology fair in Porto. “Axtra3D’s Hi-Speed SLA strikes the balance between surface quality, precision, and material flexibility,” said Maquinser CEO Christian Postigo. Andreas Tulaj, SVP Europe Sales at Axtra3D, added that Maquinser’s regional presence ensures localized support, rapid deployment, and customer-specific solutions across automotive, aerospace, energy, and mold-making sectors. Axtra3D appoints Maquinser S.A. as official reseller for Spain and Portugal. Image via Maquinser. 3MF Consortium and Ecosistema GO! Launch AM Research Initiatives On the research corner, the Microsoft-backed standards organization 3MF Consortium has formed a 6-Axis Toolpath Working Group to define open data structures for robotic and multi-axis AM workflows. The effort invites professionals using industrial robots and advanced CNC platforms to develop a 3MF extension that encodes non-planar toolpath data, enabling seamless interoperability across design, toolpath generation, and machine control software. Originally created to surpass STL and OBJ for complex manufacturing data, the 3MF format already supports units, materials, lattices, slice data, and metadata. This new working group will build on modules like the Beam Lattice Extension to integrate multi-axis motion paths, with open-source reference implementations available via the consortium’s GitHub repository. Elsewhere in Europe, Spain’s Centre for the Development of Industrial Technology (CDTI)-backed Ecosistema GO! Project (coordinated by Leitat with partners Aitiip, Idonial, Aimen, Addimat, HP, and Meltio) has launched to map national AM capabilities and drive industrial adoption. The initiative will publish a structured “map of capabilities” covering infrastructure, specialization areas, and R&D projects, while hosting workshops in automotive, energy, and aerospace to share success stories and define adoption strategies. “Ecosistema GO! aligns capabilities, generates synergies, and accelerates AM’s real incorporation into Spanish industry,” said IAM3DHUB General Secretary David Adrover. Open for new members through December 2025, the consortium aims to serve as Spain’s reference network for additive manufacturing. The 3MF Consortium invites participants to join its newly launched 6-Axis Toolpath Working Group. Image via 3MF Consortium. Dental Production Boosted by DMP Flex 200 Integration at DynaFlex In dental applications, U.S. orthodontic manufacturer DynaFlex has upgraded its digital workflow with the DMP Flex 200 metal 3D printer from 3D Systems, supplied and installed by their official supplier Nota3D. Featuring a 500 W laser and enlarged build platform, the system has increased DynaFlex’s production speeds by up to 80% for small custom components such as fixed appliances and bands. Matt Malabey, DynaFlex’s Director of Operations, noted that integrated software for orientation, nesting, and support generation further streamlines workflow: “Automation tools and improved onboarding allow us to scale smarter and faster.” The Flex 200 supports LaserForm CoCr, Stainless Steel 316 L, and Ti Gr23 alloys, aligning material properties with clinical performance standards. Prusa Research Opens EasyPrint to All Mobile Users Shifting to software, Czech desktop 3D printer maker Prusa Research has launched EasyPrint, a cloud-powered slicer embedded in the official PRUSA mobile app and accessible via Printables.com. It lets users prepare and send G-code directly from smartphones and tablets, automatically detecting compatible printers and applying the correct print profiles. An interactive 3D preview allows models to be moved, rotated, scaled and batch-arranged on virtual beds, while basic settings such as copy count and object size are consolidated into a one-click workflow. EasyPrint began as an invite-only beta used to collect performance metrics and optimize scalability before opening to everyone once preliminary tests proved the service smooth, according to Ondřej Drebota, Prusa’s Head of Country Development Managers & Partnerships Manager. All G-code generation runs in the cloud, enabling even low-powered devices to handle complex workflows, and users can download prepared files for offline printing. Prusa plans to extend EasyPrint compatibility to non-Prusa printers in future updates, broadening its reach across the 3D printing community. Nikon SLM Solutions and DynaFlex Upgrade Metal AM Workflow On 3D platform news, German metal 3D printer manufacturer Nikon SLM Solutions has integrated Freiburg’s automated depowdering specialist Solukon’s SFM-AT1500-S system at its Long Beach, California AM Technology Center. Paired to German manufacturer’s NXG 600E large-format 3D printer, the SPR-Pathfinder-driven unit handles parts up to 1,500 mm tall and 2,100 kg total weight, automating powder removal for industrial-scale metal components. Nikon SLM Solutions’ COO Gerhard Bierleutgeb stressed the importance of closely linking printing and automated depowdering for optimal production flow. Solukon’s CTO Andreas Hartmann added that the SFM-AT1500-S was custom-engineered to meet Nikon’s requirements for high-mass, complex geometries while maintaining a compact installation footprint. Andreas Hartmann, CEO/CTO of Solukon, and Joshua Forster, Production Manager at Nikon SLM Solutions. Photo via Solukon. Formnext 2025 Announces Call for Speakers Looking ahead to events, Germany’s trade-fair organizer Mesago Messe Frankfurt GmbH has opened its call for speakers for the upcoming Formnext 2025, to be held November 18-21 in Frankfurt. Submissions for the Industry Stage (covering sustainability, AI, standards, and talent) and the Application Stage (focusing on sectors like automotive, aerospace, and medical) remain open through June. Mesago’s Vice President Christoph Stüker explained that the multistage program is central to Formnext’s mission of disseminating AM knowledge and driving new applications. Additionally, Vice President Sascha F. Wenzler noted that the speaking slots offer an ideal platform for experts to share insights, build their profiles, and forge valuable industry connections. Adding to that, materials supplier participation at Formnext Asia Shenzhen 2025 has jumped 68% year-on-year, with booth bookings already at 70% capacity for the 26–28 August event at Shenzhen World Exhibition & Convention Center. The expanded materials segment, now covering advanced polymers, composites and specialised alloys, will feature over 30 exhibitors in metal powders (including Acc Material, JSJW New Material and Tiangong Technology), ceramics (Wuhan 3DCERAM, Nanoe France) and polymers (eSUN, SUNLU).  Louis Leung, Deputy General Manager of Guangzhou Guangya Messe Frankfurt, highlighted China’s rapid ascent as an AM leader, noting that national policy support and investment have fuelled double-digit growth in the domestic materials sector. Fringe activities include the 3D Print Farm Conference on filament supply chains and an expanded Laser & AM Forum, while related events, Formnext Asia Forum Tokyo (25-6 September) and Formnext Frankfurt round out the global network. Exhibitor registrations remain open online. A panel discussion recorded live at the Industry Stage during Formnext 2024. Photo via Formnext/Mesago Messe Frankfurt GmbH. Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. Ready to discover who won the 20243D Printing Industry Awards? Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights. Featured image shows a panel discussion recorded live at the Industry Stage during Formnext 2024. Photo via Formnext/Mesago Messe Frankfurt GmbH. Anyer Tenorio Lara Anyer Tenorio Lara is an emerging tech journalist passionate about uncovering the latest advances in technology and innovation. With a sharp eye for detail and a talent for storytelling, Anyer has quickly made a name for himself in the tech community. Anyer's articles aim to make complex subjects accessible and engaging for a broad audience. In addition to his writing, Anyer enjoys participating in industry events and discussions, eager to learn and share knowledge in the dynamic world of technology.

Fabric8Labs, a San Diego-based manufacturer specializing in Electrochemical Additive Manufacturing (ECAM), has been selected by AEWIN Technologies to supply thermal management components for its next generation of Edge AI systems. AEWIN, a provider of high-performance network platforms and a member of the Qisda Business Group, will integrate ECAM-produced copper components into its upcoming cooling infrastructure. The partnership addresses increasing thermal challenges in high-density computing environments. Fabric8Labs’ ECAM process enables the additive manufacturing of pure copper structures with high geometric resolution. AEWIN is deploying ECAM-based 3D micro-mesh boiler plates that increase heat exchanger surface area by over 900% and provide thermal improvements greater than 1.3 °C per 100W compared to leading conventional alternatives. “Our collaboration with AEWIN represents a significant step forward toward the future of thermal management. We are thrilled to support AEWIN by enabling them to achieve their sustainability targets and meet the growing power demands of advanced AI accelerators,” said Ian Winfield, Vice President of Product & Applications at Fabric8Labs. ECAM enables high-resolution, customized designs. Photo via Fabric8Labs. AEWIN’s system-level designs are optimized for both PFAS and PFAS-free coolants, supporting various two-phase immersion cooling methodologies. According to Dr. Liu, Director of the Advanced Technical Development Division at AEWIN Technologies, “The exponential growth of data and Edge AI complexity requires the most advanced on-premises computing. Through our advanced system-level design, we are able to leverage Fabric8Labs’ ECAM technology to optimize solutions for high efficiency, power usage effectiveness, and reduced total cost of ownership.” The ECAM manufacturing platform enables the production of 3D cooling structures without requiring powder beds or laser-based processes. Fabric8Labs’ approach allows for the fabrication of complex copper geometries suitable for thermal management applications, including capillary network designs that enhance coolant flow at the boiling interface. AEWIN reports that the use of these ECAM-enabled boiler plates supports achieving Power Usage Effectiveness (PUE) below 1.02. Founded in 2015, Fabric8Labs develops ECAM systems for electronics, medical devices, communications equipment, and semiconductor manufacturing. Its technology is designed to support dense thermal architectures in data centers and Edge AI infrastructure. The additive process is capable of producing detailed structures with reduced material waste compared to conventional subtractive or powder-based methods. AEWIN will exhibit its advanced immersion cooling platform utilizing ECAM-enabled thermal components at Computex 2025, Booth No. M0120. 3D Printed Thermal Components Expand Across Sectors Donkervoort Automobielen, a Dutch supercar manufacturer, recently partnered with Australia-based Conflux Technology to integrate 3D printed water-charge air coolers (WCAC) into its P24 RS model. Using aluminum alloys and tailored fin geometries, the Conflux-designed WCAC units reduce weight from 16 kg to just 1.4 kg per cooler. By relocating the system into the engine bay and shortening the inlet tract, the new thermal architecture enhances throttle response and packaging efficiency. The additively manufactured design, inspired by Formula 1 cooling technology, was adapted for a road-legal vehicle. In another recent example, Alloy Enterprises developed a high-efficiency cold plate for NVIDIA’s H100 PCIe card, addressing power density challenges in advanced computing. The component was fabricated from 6061 aluminum using the company’s proprietary Stack Forging process. It features 180-micron microcapillaries, gyroid infill, and monolithic inlet/outlet channels—all optimized using nTop’s generative design software. With a final weight under 550 grams, the liquid cold plate delivers targeted cooling through simulation-derived internal structures. The 3D printed aluminum cold plate. Photo via nTop. Ready to discover who won the 20243D Printing Industry Awards? Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights. Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. Featured photo shows ECAM enables high-resolution, customized designs. Photo via Fabric8Labs. Anyer Tenorio Lara Anyer Tenorio Lara is an emerging tech journalist passionate about uncovering the latest advances in technology and innovation. With a sharp eye for detail and a talent for storytelling, Anyer has quickly made a name for himself in the tech community. Anyer's articles aim to make complex subjects accessible and engaging for a broad audience. In addition to his writing, Anyer enjoys participating in industry events and discussions, eager to learn and share knowledge in the dynamic world of technology.

A new contest is underway, inviting designers and 3D printing enthusiasts to create custom accessories for the CMF Phone 2 Pro, a modular smartphone from CMF by Nothing. Organized in partnership with Czech based 3D printer manufacturer Prusa Research, the contest focuses on designs that enhance the phone’s appearance, functionality, or usability. Open for another 22 days, the contest allows each participant to submit up to five entries.  At the time of writing, 225 submissions have been received. Designers are encouraged to develop back covers, attachments, or other accessories that align with the CMF Phone 2 Pro’s structure. The phone features visible screws and a universal adaptor, making it compatible with a range of physical modifications. “We’ve teamed up with our friends at Prusa to launch a design challenge built around CMF Phone 2 Pro and its all-new Universal Cover. The best of the best will be able to bring their design to life with a brand new CMF Phone 2 Pro and Original Prusa MK4S 3D printer. Plus more prizes up for grabs,” said the CMF team. Phone Stand for CMF Phone 2 PRO. Photo via user GRZ Design/Printables. “Make tech fun” with 3D printing Entries may focus on convenience, additional features, or purely visual elements, but only accessories tailored to the CMF Phone 2 Pro will be accepted. General-purpose phone stands or unrelated designs do not qualify. To ensure accessibility, CMF has provided all the necessary files, measurements, and design references for those who don’t own the device. Prizes for the Top Three Entries: 1st Place: Original Prusa MK4S Kit and CMF Phone 2 Pro 2nd Place: CMF Phone 2 Pro, CMF Buds Pro 2, and 1200 Prusameters 3rd Place: CMF Phone 2 Pro and 800 Prusameters This isn’t the first time CMF by Nothing has involved the maker community. Last year, the brand collaborated with Chinese desktop 3D printer manufacturer Bambu Lab on a similar initiative focused on the CMF Phone 1. That contest, hosted on MakerWorld, asked designers to create custom components for the phone’s modular design. Participants had access to STEP files and technical specs to assist in the development of precise designs. The 2024 contest recognized winners in three categories: Best Functional, Best-Looking, and Most Unexpected. Judges included creators from the 3D printing space such as 3D Printing Nerd and Unnecessary Inventions, along with Nothing Co-Founder Akis Evangelidis, who emphasized the company’s commitment to co-creation with its user base. Building on that approach, the new contest continues CMF’s engagement with the design and 3D printing community, this time hosted on Printables.com, where users can find entry guidelines, design files, and current submissions. The Ultimate Magnetic Camera Cage for CMF Phone 2 PRO. Photo via user 3D Kimba/Printables. Shaping mobile accessories with 3D printing With 3D printing increasingly shaping how mobile accessories are developed, companies have started turning to open design challenges and in-house production to rethink both customization and manufacturing. Accessories company Incase and 3D printer manufacturer Carbon entered a multi-year R&D partnership to develop and mass-produce 3D printed mobile device protectors using Carbon’s Digital Light Synthesis (DLS) technology. As part of the deal, Incase gained access to 20 Carbon M2 printers, proprietary software, and exclusive rights to co-brand products made with the process.  The protectors were designed with complex lattice structures and new elastomers that offer enhanced impact protection in a lightweight form. This partnership also streamlined design and production, enabling faster iteration, reduced prototyping, and on-demand manufacturing Elsewhere, Netherlands-based 3D printer manufacturer Ultimaker kicked off a contest inviting users to design accessories for the OnePlus One smartphone and share them on Youmagine. In just a week, the platform saw a wave of submissions, with several downloadable designs quickly appearing online.  To make things interesting, Ultimaker offered participants a chance to win either an Ultimaker 2 or a OnePlus One. Once the entry period ended, the public helped narrow down the field by voting for their favorites. From those finalists, judges from both Ultimaker and OnePlus chose the top three winning designs. Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. 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, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows phone stand for CMF Phone 2 PRO. Photo via user GRZ Design/Printables.

A new review by researchers from the Beijing University of Posts and Telecommunications, CETC 54 (54th Research Institute of Electronics Technology Group Corporation), Sun Yat-sen University, Shenzhen University, and the University of Electronic Science and Technology of China surveys the latest developments in 3D printing for microelectronic and microfluidic applications. The paper released on Springer Nature Link highlights how additive manufacturing methods have reached sub-micron precision, allowing the production of devices previously limited to traditional cleanroom fabrication. High-resolution techniques like two-photon polymerization (2PP), electrohydrodynamic jet printing, and computed axial lithography (CAL) are now being used to create structures with feature sizes down to 100 nanometers. These capabilities have broad implications for biomedical sensors, flexible electronics, and microfluidic systems used in diagnostics and environmental monitoring. Overview of 3D printing applications for microelectronic and microfluidic device fabrication. Image via Springer Nature. Classification of High-Precision Additive Processes Seven categories of additive manufacturing, as defined by the American Society for Testing and Materials (ASTM) serve as the foundation for modern 3D printing workflows: binder jetting, directed energy deposition (DED), material extrusion (MEX), material jetting, powder bed fusion (PBF), sheet lamination (SHL), and vat photopolymerization (VP). Among these, 2PP provides the finest resolution, enabling the fabrication of nanoscale features for optical communication components and MEMS support structures. Inkjet-based material jetting and direct ink writing (DIW) allow patterned deposition of conductive or biological materials, including stretchable gels and ionic polymers. Binder jetting, which operates by spraying adhesives onto powdered substrates, is particularly suited for large-volume structures using metals or ceramics with minimal thermal stress. Fused deposition modeling, a form of material extrusion, continues to be widely used for its low cost and compatibility with thermoplastics. Although limited in resolution, it remains practical for building mechanical supports or sacrificial molds in soft lithography. Various micro-scale 3D printing strategies. Image via Springer Nature. 3D Printing in Microelectronics, MEMS, and Sensing Additive manufacturing is now routinely used to fabricate microsensors, microelectromechanical system (MEMS) actuators, and flexible electronics. Compared to traditional lithographic processes, 3D printing reduces material waste and bypasses the need for masks or etching steps. In one example cited by the review, flexible multi-directional sensors were printed directly onto skin-like substrates using a customized FDM platform. Another case involved a cantilever support for a micro-accelerometer produced via 2PP and coated with conductive materials through evaporation. These examples show how additive techniques can fabricate both support and functional layers with high geometric complexity. MEMS actuators fabricated with additive methods often combine printed scaffolds with conventional micromachining. A 2PP-printed spiral structure was used to house liquid metal in an electrothermal actuator. Separately, FDM was used to print a MEMS switch, combining conductive PLA and polyvinyl alcohol as the sacrificial layer. However, achieving the mechanical precision needed for switching elements remains a barrier for fully integrated use. 3D printing material and preparation methods. Image via Springer Nature. Development of Functional Inks and Composite Materials Microelectronic applications depend on the availability of printable materials with specific electrical, mechanical, or chemical properties. MXene-based conductive inks, metal particle suspensions, and piezoelectric composites are being optimized for use in DIW, inkjet, and light-curing platforms. Researchers have fabricated planar asymmetric micro-supercapacitors using ink composed of nickel sulfide on nitrogen-doped MXene. These devices demonstrate increased voltage windows (up to 1.5 V) and volumetric capacitance, meeting the demands of compact power systems. Other work involves composite hydrogels with ionic conductivity and high tensile stretch, used in flexible biosensing applications. PEDOT:PSS, a common conductive polymer, has been formulated into a high-resolution ink using lyophilization and re-dispersion in photocurable matrices. These formulations are used to create electrode arrays for neural probes and flexible circuits. Multiphoton lithography has also been applied to print complex 3D structures from organic semiconductor resins. Bioelectronic applications are driving the need for biocompatible inks that can perform reliably in wet and dynamic environments. One group incorporated graphene nanoplatelets and carbon nanotubes into ink for multi-jet fusion, producing pressure sensors with high mechanical durability and signal sensitivity. 3D printed electronics achieved through the integration of active initiators into printing materials. Image via Springer Nature. Microfluidic Devices Fabricated via Direct and Indirect Methods Microfluidic systems have traditionally relied on soft lithography techniques using polydimethylsiloxane (PDMS). Additive manufacturing now offers alternatives through both direct printing of fluidic chips and indirect fabrication using 3D printed molds. Direct fabrication using SLA, DLP, or inkjet-based systems allows the rapid prototyping of chips with integrated reservoirs and channels. However, achieving sub-100 µm channels requires careful calibration. One group demonstrated channels as small as 18 µm × 20 µm using a customized DLP printer. Indirect fabrication relies on printing sacrificial or reusable molds, followed by casting and demolding. PLA, ABS, and resin-based molds are commonly used, depending on whether water-soluble or solvent-dissolvable materials are preferred. These techniques are compatible with PDMS and reduce reliance on photolithography equipment. Surface roughness and optical transparency remain concerns. FDM-printed molds often introduce layer artifacts, while uncured resin in SLA methods can leach toxins or inhibit PDMS curing. Some teams address these issues by polishing surfaces post-print or chemically treating molds to improve release characteristics. Integration and Future Directions for Microdevices 3D printed microfluidic devices in biology and chemistry.Image via Springer Nature. 3D printing is increasingly enabling the integration of structural, electrical, and sensing components into single build processes. Multi-material printers are beginning to produce substrates, conductive paths, and dielectric layers in tandem, although component embedding still requires manual intervention. Applications in wearable electronics, flexible sensors, and soft robotics continue to expand. Stretchable conductors printed onto elastomeric backings are being used to simulate mechanoreceptors and thermoreceptors for electronic skin systems. Piezoelectric materials such as BaTiO₃-PVDF composites are under investigation for printed actuators and energy harvesters. MEMS fabrication remains constrained by the mechanical limitations of printable materials. Silicon continues to dominate high-performance actuators due to its stiffness and precision. Additive methods are currently better suited for producing packaging, connectors, and sacrificial scaffolds within MEMS systems. Multi-photon and light-assisted processes are being explored for producing active devices like microcapacitors and accelerometers. Recent work demonstrated the use of 2PP to fabricate nitrogen-vacancy center–based quantum sensors, capable of detecting thermal and magnetic fluctuations in microscopic environments. As materials, resolution, and system integration improve, 3D printing is poised to shift from peripheral use to a central role in microsystem design and production.  3D printing micro-nano devices. Image via Springer Nature. Ready to discover who won the 20243D Printing Industry Awards? Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights. Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. Featured image shows an Overview of 3D printing applications for microelectronic and microfluidic device fabrication. Image via Springer Nature. Anyer Tenorio Lara Anyer Tenorio Lara is an emerging tech journalist passionate about uncovering the latest advances in technology and innovation. With a sharp eye for detail and a talent for storytelling, Anyer has quickly made a name for himself in the tech community. Anyer's articles aim to make complex subjects accessible and engaging for a broad audience. In addition to his writing, Anyer enjoys participating in industry events and discussions, eager to learn and share knowledge in the dynamic world of technology.

Researchers at the German Aerospace Center (DLR) have developed MiniFix, a fully 3D printed syringe-based biological fixation system engineered for spaceflight. Successfully deployed in five MAPHEUS sounding rocket missions, MiniFix represents a breakthrough in experimental payload design, combining rapid prototyping, modularity, and robust performance in microgravity environments, combining rapid prototyping with modular, lightweight, and reliable performance under the extreme conditions of microgravity research. A 3D printing milestone for space life science Unlike conventional biological fixation systems, MiniFix is entirely produced via Fused Deposition Modeling (FDM). Key components, including the syringe holders, baseplate, and housing, were fabricated using desktop 3D printers, notably a Prusa MK3+, with 0.4 mm nozzles and a 0.3 mm layer height. This approach enabled fast, low-cost iteration and customization of parts to suit different missions and experimental needs. The system has undergone structural revisions using three different filaments; PLA (Polylactic Acid), used in initial missions (MAPHEUS-09 and -12), PETG (Polyethylene Terephthalate Glycol), chosen for enhanced mechanical durability (MAPHEUS-14), and GreenTEC Pro, a compostable bioplastic with high thermal resistance, used in MAPHEUS-15. This made MiniFix the first biologically compostable experiment structure to fly aboard a rocket. Sectional, translucent view through the MiniFix fixation system. Image via Sebastian Feles / DLR. Modular design for rapid adaptation MiniFix features a dual-syringe configuration, where a fixative and a biological sample are housed in vertically stacked syringes. Syringe actuation is handled by NEMA11 stepper motors coupled with linear actuators, allowing precise fluid dispensing. The hardware is modular and sterilizable, enabling pre-assembled syringe units to be installed under sterile conditions. Its all-3D printed chassis ensures that custom features, like integrated lighting for plant experiments, can be introduced quickly without redesigning the core system. This makes MiniFix suitable for various biological models, from unicellular organisms to organoids. Variants of the SBBFS Configuration. Image via Sebastian Feles / DLR. Built-in thermal regulation via waste heat A standout innovation is MiniFix’s passive thermal management system, which uses the heat generated by its stepper motors to maintain stable internal temperatures. With no need for separate heating elements, this system simplifies design, reduces power draw, and lowers overall payload mass, critical factors for sounding rocket missions with strict weight and energy budgets. Test data from MAPHEUS-15 showed that MiniFix maintained an internal temperature of 21.98 °C ±0.12 °C, consuming just 4.6 Wh during operation, even under ambient conditions as low as 4 °C. Space-tested reliability The reliability of this 3D printed structure was put to the test across multiple missions. MiniFix successfully endured extreme conditions, including launch vibrations exceeding 20 g and temperature swings from hypergravity to microgravity and re-entry. Across four missions, its components have shown no degradation or material failure, with post-flight inspections confirming the integrity of all printed parts and mechanical systems. Future applications Beyond fixation, MiniFix could evolve into a general-purpose liquid handling system for space. Its syringe mechanism is already capable of performing programmable mixing and the platform could be adapted for reagent delivery, drug testing, or even microfluidics in space-based manufacturing. Additionally, it exemplifies how additive manufacturing can accelerate experimental development cycles while maintaining reliability in harsh environments. Its open-source microcontroller and modular design ethos further position it as a template for future experimental hardware in life sciences and beyond.3D printing gains traction in space hardware development Additive manufacturing is rapidly transforming the development of spaceflight hardware, from on‑orbit part fabrication to ground-based launch systems. Just this year, ESA’s Metal3D printer aboard the ISS produced the first metal 3D‑printed part in microgravity, now safely back on Earth for analysis. Meanwhile, Nikon and JAXA are collaborating to refine large-scale metal 3D printing for space components, advancing materials and process control to shorten lead times and reduce launch costs. Within this context, DLR’s MiniFix system exemplifies a new wave of highly adaptable, mission‑specific payloads, completely fabricated using desktop FDM printers and bioplastics, optimized for the rigors of sounding rocket flight and microgravity research. The full research paper, titled “Pioneering the Future of Experimental Space Hardware,” is available in Microgravity Science and Technology via Springer Nature. Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us onLinkedIn and subscribe to the 3D Printing Industry YouTube channel to access more exclusive content. At 3DPI, our mission is to deliver high-quality journalism, technical insight, and industry intelligence to professionals across the AM ecosystem.Help us shape the future of 3D printing industry news with our2025 reader survey. Featured image shows sectional, translucent view through the MiniFix fixation system. Image via Sebastian Feles / DLR.

A review published in Virtual and Physical Prototyping explores the growing field of additively manufactured acoustic metamaterials (ACA-Meta), highlighting how 3D printing technologies enable novel designs for effective sound absorption across diverse applications. Authored by researchers from Khalifa University and Dassault Aviation, the paper classifies acoustic metamaterials into perforated, slotted, cellular, and hybrid types and investigates how additive manufacturing enhances their performance. Expanding acoustic control with 3D printing Additive manufacturing offers unique benefits for acoustic metamaterials, enabling precise control over geometry, material distribution, and internal architecture. This level of control allows researchers and engineers to tailor acoustic behavior at specific frequency ranges, while simultaneously optimizing for weight, mechanical strength, and structural complexity.  Traditional sound-absorbing materials, such as porous foams or fibrous panels, are often constrained by fixed properties and limited adaptability. In contrast, 3D printing allows designers to create resonant structures and internal cavities with sub-wavelength precision, an essential factor in manipulating how sound waves interact with matter. The review outlines how techniques such as Stereolithography (SLA), Selective Laser Melting (SLM), Fused Deposition Modeling (FDM), and Digital Light Processing (DLP) are being employed to fabricate a new generation of acoustic absorbers. These processes enable the construction of intricate geometries previously unattainable with conventional manufacturing, and allow for the fine-tuning of key parameters such as pore size, wall thickness, infill density, and material gradients. In doing so, additive manufacturing not only improves absorption efficiency but also broadens the usable frequency range of these metamaterials, making them more adaptable to specific environments and industrial requirements. ACA-Meta fabricated by various additive manufactured techniques: a) vat photopolymerization, b) powder bed fusion, c) binder jetting, d) extrusion, and e) material jetting. Image via V. Sekar et al., Virtual and Physical Prototyping. The paper categorizes these acoustic metamaterials into four structural families, each with distinctive mechanisms for managing sound waves. Perforated metamaterials absorb mid- to high-frequency noise by dissipating energy through arrays of micro-holes, often backed by air cavities to enhance low-frequency performance. Slotted designs employ labyrinthine or coiled channels to extend the acoustic path length, enabling effective attenuation at low frequencies within a compact footprint. Cellular structures, including periodic honeycombs, gyroids, and stochastic foams, are engineered to exhibit broadband performance through controlled porosity and internal resonance. Lastly, hybrid designs combine multiple features, such as perforated faces with embedded coiled cavities or layered cellular cores, to achieve tunable, wideband absorption across multiple acoustic regimes. Classification and sub classification of ACA-Meta. Image via V. Sekar et al., Virtual and Physical Prototyping. These classifications are not merely theoretical; each has been demonstrated through experimental validation, with performance metrics such as sound absorption coefficient (SAC) measured using impedance tubes and reverberation chambers. The paper emphasizes that even minor design modifications, like altering the angle of perforations or grading cell density, can have significant effects on absorption performance, reinforcing the value of additive manufacturing as both a prototyping and production tool in acoustic engineering. Simulation and experimental validation To quantify acoustic absorption, the study reviews both analytical models and experimental methods. Key parameters include the sound absorption coefficient (SAC), surface porosity, and sample orientation. Validation techniques such as impedance tube and reverberation room testing show that additively manufactured metamaterials can achieve or exceed the performance of traditional absorbers. The review also identifies future directions, including volumetric 3D printing, multi-material printing, and 4D printing using smart materials for tunable acoustic responses. These approaches promise scalable, reconfigurable absorbers that can adapt to environmental changes or user-defined inputs. Schematic representation and design parameters of ACA-Meta. Image via V. Sekar et al., Virtual and Physical Prototyping. Reshaping acoustic metamaterials Interest in the acoustic capabilities of 3D printing has grown significantly in recent years. In 2019, researchers at the University of Sussex demonstrated a 3D printed metamaterial capable of directing sound to a specific location without the use of headphones, an early example of how additive manufacturing could redefine personal audio delivery. More recently, the University of Strathclyde received £500,000 in funding to develop miniaturized acoustic systems using 3D printing, aiming to advance compact and high-performance devices for sensing and communication. Consumer audio brands have also embraced the technology; Campfire Audio, for instance, leveraged additive manufacturing to create earphones internal structure for their Supermoon series, optimizing both sound performance and fit. On a more experimental front, researchers have begun using sound itself as a medium for fabrication, as seen in a recent study on holographic Direct Sound Printing (DSP), which manipulates ultrasonic fields to solidify resin. Together, these developments underscore the growing convergence of 3D printing and acoustic innovation, a convergence that the reviewed paper situates within the emerging domain of engineered sound-absorbing metamaterials. Read the full article in Virtual and Physical Prototyping Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us onLinkedIn and subscribe to the 3D Printing Industry YouTube channel to access more exclusive content. At 3DPI, our mission is to deliver high-quality journalism, technical insight, and industry intelligence to professionals across the AM ecosystem.Help us shape the future of 3D printing industry news with our2025 reader survey. Feature image shows ACA-Meta fabricated by various additive manufactured techniques.