Researchers from MITs Computer Science and Artificial Intelligence Laboratory (CSAIL), Zhejiang University, and Tsinghua University have developed a new approach for 3D printing objects capable of humanlike movement. Called Xstrings, the method automates the fabrication of cable-driven assemblies that can bend, coil, screw, and compress.Such devices are traditionally difficult to produce because the cable must be manually embedded throughout the object. However, the Xstrings method leverages multi-material FDM 3D printing to embed cables directly within the structure in a single step, eliminating manual assembly requirements. The team has also developed a digital design tool that allows users to generate 3D print files of cable-driven components with desired movement capabilities.Jiaji Li, lead author, and MIT CSAIL postdoc, will present the new research paper during next months 2025 Conference on Human Factors in Computing Systems (CHI2025). It outlines several tests used to validate Xstrings capabilities. For instance, Lis team confirmed that the 3D printed cables survived over 60,000 90-degree contractions before breaking. Additionally, production speed impacted cable quality, with 10 mm/s and 15 mm/s yielding optimal results when 3D printing at 260C. According to Li, Xstrings can reduce total production time by 40%.Ultimately, the researchers believe their new approach offers value for applications including cable-driven robots for space stations and extraterrestrial bases, bionic devices, adjustable fashion designs, and interactive artwork installations.The Xstrings software can bring a variety of ideas to life. It enables you to produce a bionic robot device like a human hand, mimicking our own gripping capabilities, Li explained. Our innovative method can help anyone design and fabricate cable-driven products with a desktop bi-material 3D printer.Jiaji Li and a device 3D printed using the Xstrings method. Photo via MIT CSAIL.MIT introduces new bionics 3D printing methodCable-driven mechanisms function by threading a wire through a segmented object. Pulling the wire creates tension, causing the object to bend, twist, or fold, depending on its design. Such approaches are frequently used in bionics, allowing robotic devices to exhibit anthropomorphic movement. For instance, adding cables to a robotic hand can enable the fingers to curl and grip objectsMITs Xstrings software uses Rhinoceros 8 as its design environment and Grasshopper as an intermediary computational tool. The workflow begins with a user submitting a design with specific dimensions. They then choose one of four motion primitives, Bend, Coil, Twist, or Compress, to define how their device will move. Users can also input the desired angle for these motions.Notably, multiple primitives can be combined into a single device to unlock greater motion capabilities. For instance, when creating a robotic claw, the researchers integrated multiple cables in a parallel combination, allowing each finger to close into a fist. They used their Xstrings method and design tool to 3D print several other multi-material mechanisms. These included a walking lizard robot, a wall sculpture that can be opened and closed, and a tentacle that can coil around objects.Xstrings also allows users to determine where each cable is secured within their parts. This includes selecting the endpoint where the cable is fixed (the anchor), the holes the cable passes through (threaded areas), and where the cable is pulled to operate the device (the exposed point). For example, a robotic finger might include an anchor at the fingertip and a cable that runs down the finger to an exposed pull tag at the other end.After simulating the design, users can export their files and send them to an FDM 3D printer. To ensure compatibility with any multi-material FDM 3D printer, the researchers chose not to generate G-code for a specific model. Instead, Lis team has provided parameter settings for various slicing software and 3D printed their Xstrings test devices using an UltiMaker S5, UltiMaker 3, and Bambu Lab X1. They fabricated the main body of each device with PLA and used Nylon filament for the cable.MITs new process creates functional parts in a single step by positioning horizontal cables and printing around them. So far, this method has been used to produce parts with a rigid exterior and a soft, flexible interior. In the future, the researchers aim to reverse this structure by 3D printing devices with a soft exterior and a rigid interior, mimicking human skin and bones. They also plan to explore more durable cables and experiment with embedding them at different angles or vertically.Li co-authored the paper with Shuyue Feng, a masters student at Zhejiang University, and Yujia Liu from Tsinghua University. Guanyun Wang, an assistant professor at Zhejiang University and former MIT Media Lab visiting researcher, also contributed. The team included three CSAIL members: Maxine Perroni-Scharf, an MIT PhD student in electrical engineering and computer science, and Emily Guan, a visiting researcher. Senior author Stefanie Mueller is the TIBCO Career Development Associate Professor at MIT in Electrical Engineering, Computer Science, and Mechanical Engineering.An Xstrings 3D printed cable-driven finger. Image via MIT CSAIL.3D printing bionics3D printing is being increasingly adopted to fabricate bionic devices, particularly for prosthesis applications.Earlier this month, researchers from Johns Hopkins University, Florida Atlantic University, and the University of Illinois Chicago developed a 3D printed prosthetic hand that mimics human touch. The new offering combines rigidity and dexterity, boasting a grip strong enough to securely hold a water bottle and delicate enough to pick up a fragile plastic cup without damaging it.Its hybrid robotic fingers feature three independently actuated soft joints made by chemical manufacturing firm Smooth-Ons Dragon Skin 10 silicone. These are supported by rigid skeletal structures 3D printed in PLA. Analysis and testing have reportedly shown that each hybrid robotic finger can achieve 130 curvature and a flexion angle of 208 at an actuation pressure of just 7 psi. This is more efficient than purely soft robotic fingers which require much higher pressures. In fact, during testing, the hybrid finger demonstrated over three times the grasping force of soft robotic alternatives.Last year, UK-based robotics company Open Bionics announced that a hand amputee from London had adopted its 3D printed finger device for the first time. The prosthesis called the Hero Gauntlet, helps people with congenital or acquired partial hand-limb differences regain hand functionality. Open Bionics customizes each device using 3D scanning and additive manufacturing technology. Users control the gripping action by flexing their wrists.In other news, US-based prosthesis manufacturer Psyonic developed a 3D printed Bionic Hand using Formlabs Form 3 stereolithography (SLA) 3D printer. The development process included rapid prototyping, design iterations, and low-volume production of end-use parts. The Ability Hand weighs just 490 grams. Its thumb rotates electrically and manually, while all five fingers can flex to provide full hand functionality.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 Jiaji Li and a device 3D printed using the Xstrings method. Photo via MIT CSAIL.

It was a lively day at Rapid Fusions South West UK headquarters, where guests gathered under a marquee on an airstrip-adjacent site to witness a 3D printing first. Over conversation, coffee, and paella, co-founders Jake Hand and Martin Jewell introduced Medusa, a large-scale hybrid manufacturing system that merges high-speed material deposition with integrated CNC finishing. Developed over 18 months, Medusa aims to tackle challenges that have long confined additive manufacturing to prototyping rather than true production.The launch is noteworthy for several reasons; companies are proceeding cautiously with CAPEX investments, creating a ripple effect across hardware sales, software, and services in AM. Rapid Fusion is well positioned to glean such insight, the company is a spin-out of Evo3D a well-established 3D printer reseller with its offices and showroom above the workshop that now houses the first Medusa 3D printer, and also the Apollo platform: an earlier example of the high deposition pellet based 3D printing approach often referred to as Large Format Additive Manufacturing (LFAM).The Rapid Fusion Medusa. Photo by Michael Petch.From Concept to PrototypeHand recalled how Medusas inception began, quite literally, on the back of a [cigarette] packet. Yet, in under two years, Rapid Fusion advanced the concept into a robust industrial prototype. CTO Martin Jewell explained that the teams mission revolved around four key barriers blocking the mainstream adoption of additive manufacturing: speed, scale, fragmented workflows, and reliability.Medusa itself is not just another 3D printer, Jewell said. The one-click workflow and CNC finishing capabilities integrated within this system are transformational. Medusas hefty 22-kilogram toolhead moves at speeds of up to 1.2 meters per second, depositing material at rates of 17 kilograms per hour. This performance stems from an industrial-strength chassisbuilt like a literal tank, as Jewell described itensuring stability even under rapid, heavy-payload movement.Rapid Fusion has achieved this without VC funding and plans to stay agile, continuously iterating rather than sticking to rigid product cycles. They believe hardware-focused companies can suffer under VC expectations. Other businesses release a product and then run it until nobody buys it anymore. We dont operate that way, said Jewell.The company is also rapidly protecting intellectual property due to heightened competitor interest. Jewell said, We had to file three patents this morning because were showing the technology today. Once its in the public domain, you lose the ability to file. Competitors have downloaded all the materials from our website in the last two weeks. Its not ego; these are just facts, added Hand.3D printing on the Rapid Fusion Medusa. Photo by Michael Petch.Closing the Gap Between Additive and SubtractiveA standout feature of Medusa is its ability to combine additive and subtractive steps in a single automated workflow. The system integrates multiple printing heads for filament and pellet extrusion, as well as a CNC milling tool. Jewell stressed how this allows for seamless, no-hands transitions between printing and finishing, cutting lead times by around 60% compared to traditional processes.He also highlighted the systems advanced sensor suite and thermal visualization, which not only track real-time performance but will eventually enable predictive maintenance. Were looking at the long game, Jewell said. Its about reliability, minimizing downtime, and upgrading machine intelligence over time.Medusas modular design further underscores its adaptability and ease of service. Critical componentsincluding the machines braincan be swapped or upgraded in about 45 minutes, reducing extended outages and future-proofing customer investments.You could essentially do a brain transplant on the machine in about 45 minutes, Jewell explained. It means you dont need to replace the entire unit; you can upgrade components individually.Software Integration with AI BuildRapid Fusions hardware breakthroughs dovetail with automation-driven software provided by AI Build, a London-based company specializing in software for AM and hybrid manufacturing. Guy Brown, Head of R&D at AI Build, underscored the importance of a unified platform that spans every stage of manufacturing, from uploading design files to real-time process monitoring.Weve been printing in the lab for 10 years, and weve had a lot of failures, Brown said. All that pain has been turned into lessons learned and baked into our software.AI Builds platform automatically checks designs for additive manufacturing suitability, slices and simulates the toolpaths, and oversees process control. The system also introduces hybrid toolpathing, enabling subtractive stepstrimming or smoothing just a few millimetersin the same environment. This approach delivers high-quality surface finishes comparable to more complex multi-axis milling machines.Moreover, AI Build created a digital twin of the Medusa system to ensure collision detection and safe operations. A tailored post-processor handles tool-change macros that let customers easily calibrate their machines. Brown also highlighted AI Builds starter software, featuring a one-click slicing interface with nine preconfigured strategies. This simplified approach lowers the barrier to entry for those transitioning from smaller desktop 3D printers.This helps users reach their first print as fast as possible, he noted. Its about streamlining that learning curve so you can go from zero to functional part in a fraction of the usual time.Theres nobody in a factory setting thinking, I want a robot that prints. They think, I want to make a moldwhat are my options? So they talk to their integrators, said Hand. Traditional robot integrators and manufacturers, like ABB, KUKA, FANUC, are slowly recognizing large-format printings potential. FANUC is more open; KUKA and ABB are cautious.Thermal Shield and Real-Time MonitoringAI Builds Thermal Shield is a key software innovation, an infrared camera-based monitoring feature that checks interlayer temperatures during printing. The system automatically adjusts print settings to maintain optimal thermal conditions, preventing layers from overheating or cooling too rapidly.Thermal monitoring brings down the barrier to entry dramatically, Brown said, emphasizing how newer operators might miss subtle temperature cues an experienced operator would catch. The technology also logs comprehensive process data, enabling traceability vital for aerospace, automotive, and other sectors that demand rigorous quality control.Rapid Fusion envisions self-optimizing machines via on-prem AI, but data-sharing hurdles remain. They aim to integrate NVIDIA modules for localized machine learning without exposing sensitive data. Weve built the hardware infrastructure to enable AI-driven printing The next step is for it to adjust the process automatically, said Jewell.Thermal Camera on the Rapid Fusion Medusa. Photo by Michael Petch.De-Risking Through Simulation and ComplianceThe National Manufacturing Institute Scotland (NMIS) provided crucial input for Medusas development, focusing on simulation, risk assessment, and regulatory compliance. Dickon Walker, an R&D engineer at NMIS, explained that his team coordinated an industry steering group to gather real-world feedback, ensuring the printers design aligned with genuine production scenarios.NMIS conducted finite element analysis (FEA) to assess structural stability under Medusas high-speed, heavy-load conditions. Minor deviationsless than one millimeter across a large build volumewere uncovered through laser trackers and optical coordinate measuring systems. While small, these deviations still prompted hardware refinements.We simulated how the printer frame behaves when driving such a heavy tool at high speeds, Walker said. Though the deviations were under one millimeter, we aimed to refine alignment further.Beyond structural testing, NMIS managed CE marking guidelines, essential for market acceptance. Walker acknowledged that preparing technical files is not the sexiest part of engineering but remains critical for commercializing the machine. NMIS also validated mechanical properties by printing test samples on Medusa rather than relying on generic datasheets, which often reflect injection-molded rather than 3D-printed characteristics.Sustainable Materials With FilamentiveRavi Toor, founder and director of Filamentive, underscored the sustainability aspect of the Medusa project. While additive manufacturing is considered inherently less wasteful than subtractive processes, Toor cautioned against overlooking plastic consumption and end-of-life recycling.Pellet-based printingone of Medusas capabilitieseliminates spool waste and requires less energy than producing filament. The approach also encourages the use of locally sourced recycled materials, further cutting carbon footprints. In parallel, Medusas filament extruder allows high-detail prints and access to a broader array of materials.We cant ignore plastic consumption or recycling at the end of life, Toor noted. Pellet-based printing cuts waste from spools and reduces energy usage, while also making it easier to integrate recycled feedstock.Filamentive tested polymer blends such as recycled PETG or polycarbonate reinforced with glass fiber, achieving heat resistance above 100 degrees Celsius. Some of these blends reduce carbon emissions by up to 60% compared to virgin materials. Toor also praised Medusas modularity, which lets users replace only faulty componentslike the heated bed or extruderrather than discarding the entire machine.On the decision to use open materials and pelletised feedstock Hand said, Charging 200 to 300 for a kilo of PLA? Its insane. Its just the business modelkeeping customers locked in Were more focused on delivering the best solution, making a profit, and not exploiting the buyer. Rapid Fusion rejects closed systems and high material markups that trap users into overpriced consumables. They view this as a barrier to mainstream adoption.Backing from Innovate UKChaco van der Sijp, Innovation Lead at Innovate UK, likened attending Medusas launch to a parent at a childs graduation. Innovate UK, the UKs innovation agency, provided funding and strategic guidance, helping Rapid Fusion, AI Build, Filamentive, and NMIS iterate quickly and minimize risk.Were extremely thrilled with how this has panned out, said van der Sijp. Scaling large-format is a bold move, but were going to get there one day.He noted that additive manufacturing still faces skepticism regarding scalability and automations potential impact on employment. Innovate UKs stance is that automation, when done correctly, fosters new high-level jobs.Van der Sijp highlighted Medusas integrated approachcovering material sourcing, design, supply chain management, fabrication, and circular reuseas key to genuine transformation. By addressing the entire manufacturing ecosystem, Medusa aims to push additive technologies closer to a mainstream, globally recognized manufacturing solution.A Glimpse into the Future of Additive ManufacturingFrom the robust build of its chassis to the advanced software stack that orchestrates both printing and CNC finishing, Medusa represents a comprehensive step forward in industrial 3D printing. The collaboration between Rapid Fusion, AI Build, NMIS, Filamentive, and Innovate UK underscores a united push to overcome long-standing hurdlesspeed, scale, workflow integration, reliability, and sustainability.Rapid Fusion pegs the large-format markets annual TAM at 1520 million. They see themselves among the top three global players, aiming to expand demand rather than battle for a small pie.If the excitement at Rapid Fusions unveiling is any indication, Medusa may well represent an important moment for additive manufacturing in the UK, closing the gap between prototype-friendly 3D printers and the reliable, scalable systems that industries have long demanded.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.Featured image shows the Rapid Fusion Medusa launch. Photo by Michael Petch.Michael PetchMichael Petch is the editor-in-chief at 3DPI and the author of several books on 3D printing. He is a regular keynote speaker at technology conferences where he has delivered presentations such as 3D printing with graphene and ceramics and the use of technology to enhance food security. Michael is most interested in the science behind emerging technology and the accompanying economic and social implications.

RAPID + TCT returns to the home of US automotive manufacturing in 2025. North Americas largest 3D printing trade show will run at Detroits Huntington Place between April 8-10.Over 400 additive manufacturing companies will attend the show, which is co-locating with SMEs AeroDef Manufacturing and SAE Internationals WCX in the Motor City. As the largest technical mobility event in the US, WCX will be complemented by RAPID + TCTs stacked automotive conference track. Over the three-day 3D printing event, fifteen presentations will explore key mobility topics, including upcycling, end-use production, design, and development.On day one of RAPID + TCT 2025, Erik Riha and Fadi Abro will discuss how leading automaker Ford Motor Company is leveraging Stratasys 3D printers to enhance prototyping and product validation. I recently spoke with Riha, a Prototype Technical Specialist at Ford, and Abro, Stratasys Global Automotive Director, to learn more about their collaboration. They highlighted the value of 3D printing for car development, describing it as a critical tool in the toolbox.Boasting three decades of automotive experience, Riha uses additive manufacturing to aid product development, rather than for iterating designs. Based out of Fords Product Development Center in Dearborn, Michigan, his team fabricates jigs, fixtures, and surrogate parts such as test car bodies. These are used to assess and validate vehicle assembly and manufacturability. Theres not one part of the vehicle we havent touched, Riha explained.Abro called Stratasys F3300 3D printer, recently adopted by Ford, a step change in how FDM works and produces parts. He highlighted how the system speeds up high-quality part production, enabling Ford to stay productive, meet demand, and reduce costs.Stratasys automotive expert also addressed misconceptions surrounding the rise of low-cost desktop 3D printers. While acknowledging that desktop hobbyist units have a home in education and maker spaces, Abro believes they cannot match Stratasys performance for industrial applications. He explained why these consumer-level offerings hurt our business and taint the image of additive.Are you interested in attending RAPID + TCT 2025? 3D Printing Industry readers can claim a complimentary expo pass with the promo code 3DPI. Sign up today at the official RAPID + TCT website.The show floor at RAPID + TCT 2024. Photo via SME.Ford and Stratasys at RAPID + TCT 2025At 11:00 AM EDT on Tuesday, April 8, Riha and Abro will take to the stage to discuss the value of additive manufacturing for automotive product development. Rihas going to cover Fords use of additive manufacturing and its applications, and Ill talk about whats new at Stratasys, explained Abro. Fords prototyping expert added that the session will include performance comparisons and case studies of complex prototype assemblies produced with 3D printing.Stratasys F3300 3D printer will be at the crux of the conversation. According to Riha and Abro, Fords adoption of the Stratasys F3300 3D printer is less about unlocking new applications and more about streamlining manufacturing processes. The Michigan-based automaker already employs a fleet of Stratasys FDM printers, including the Fortus 900mc.Riha explained that his team recently acquired its new Stratasys 3D printer after moving to a larger facility with higher production demands. Initially, he considered purchasing another 900mc because of its proven reliability and 24-hour operation. However, the F3300 quickly emerged as the better choice due to its superior speed, efficiency, and part quality. In terms of throughput, it has outperformed our 900s, Riha said. Its now our flagship 3D printer and has proven to be incredibly robust.The F3300s enhanced productivity and efficiency stems from its ability to self-calibrate, eliminating manual setup requirements. Faster calibration, in turn, reduces labor costs, which our customers have been asking for for years, explained Abro. Riha added that this level of automation saves valuable time, particularly when engineers are juggling urgent print jobs.Stratasys latest FDM 3D printer initially raised concerns for Ford due to its reduced size. The large-scale Fortus 900mc boasts a 914 x 610 x 914 mm build volume, compared to 600 x 600 x 800 mm offered by the F3300. However, Abro revealed that the 3D printer can accommodate 8085% of typical parts. If youre printing a six-foot part, the biggest printer we have cant do that either, so youre splitting those parts anyway, explained the global automotive director. Once I looked at it, Fadi was right, Riha added. Most of our large parts already need to be made in two sections and glued together.The Stratasys F3300 3D printer. Photo via Stratasys.3D printing at FordThe automotive AM experts argue that the value of 3D printing for automotive applications is not in the mass production of end-use consumer parts. Instead, Abro believes the middle category between the design and fabrication stages is where additive belongs. This includes design validation with surrogate and trial parts, producing jigs and fixtures, and 3D printing tools to make components.According to Abro, Stratasys 3D printers are producing jigs and fixtures in over 20 automotive plants to help get cars out the door. This, he added, is much more beneficial than 3D printing a little widget that goes in the car. For example, he pointed to Fords F-150 pickup truck. If you can produce ten more of those a day using additive tooling, Ford can make $1 million more at that plant.Rihas role at Ford fits into the design validation stage of Abros middle category. His team uses Stratasys technology to validate the assembly process and 3D print surrogate parts for testing. The prototyping experts team 3D printed about 18,000 parts last year, mostly one-offs, with some as large as a lift gate. Some people assume prototyping means 3D printing something, looking at it, and throwing it away before moving to design iteration Abro added. This is not what Eriks team is doing. They are prototyping so that the manufacturing can be done correctly.Automotive parts 3D printed on the F3300. Photo via Stratasys.Riha noted that Ford often fabricates full-sized, drivable test vehicles to validate parts before final manufacturing stages. His primary responsibility is to ensure that the parts we produce for these vehicles provide the best value for Ford. Stratasys technology also plays a key role in quickly producing one-off brackets needed to mount specific components during testing.Fords prototyping expert emphasized that additive manufacturing is not used for all applications. Instead, his teams 30+ 3D printers are leveraged alongside conventional subtractive methods like injection molding and stamping machine presses. We look at it on a case-by-case basis. If we need something quick, 3D printing is usually the way to go, Riha noted. It all depends on what the part is, what the application is, how much time we have.He added that 3D printing enables Ford to go from CAD to part in just a few hours, something you cant do with conventional injection molding and stamping. However, 3D printing struggles to replicate the properties of injection-molded parts, making it less suitable for those use cases. Its a tool in a tool belt. When it makes sense, you use it, Abro said, emphasizing that it shouldnt be forced into applications better suited for other production methods.While digital simulation tools powered by AI and machine learning are becoming more prominent, physical testing remains a critical step in product development. Simulation isnt everything, explained Abro. A lot of parts have to be hand-tested because CAD isnt going to catch everything.Riha shared an example where his team machined the back end of a vehicle and 3D printed the lift gate to assess its assembly and functionality. When assembling the battery charging port, engineers realized the original stud placement made it inaccessible during the planned assembly sequence, an issue the digital simulations had missed. Rihas team quickly built a physical model, allowing engineers to modify and test the assembly process before finalizing their design. If they had discovered that in the production plant, it would have cost a ton of money to fix, Riha added.Automotive parts 3D printed using Stratasys technology. Photo via Stratasys.Industrial manufacturing vs. Hobbyist 3D printersOver recent years, low-cost, entry-level desktop 3D printers have been increasingly adopted for professional applications that dont require advanced materials. Abro addressed misconceptions about these consumer-level products. Sometimes people misconstrue what you can get out of a hobbyist printer versus what you would get out of an industrial printer, he explained. These things are night and day.Abro compared the disparity with the difference between a scooter and an F-150. Theyre both modes of transportation, but they are not the same. If you need to haul drywall, youre going with the F-150, not the scooter.He added that low-cost desktop FDM 3D printers damage Stratasys business and the 3D printing industry. According to Abro, potential customers will adopt a cheaper desktop hobby type system and have a bad experience because it doesnt meet their quality and reliability requirements. Stratasys automotive expert believes these experiences taint the image of additive, a core message he will push during RAPID + TCT 2025.The Stratasys F3300s extruders. Photo via Stratasys.The future of 3D printing for automotive at RAPID + TCT 2025During RAPID + TCT 2025, Riha is looking forward to exploring recycling technologies, intending to increase the sustainability of his operations. I want to see if theres some avenue where I can try to reclaim some of the materials we use, he added.Riha also expressed his intention to adopt metal 3D printing technology in the future. While Ford does possess metal 3D printers, metal additive capabilities are currently absent at Rihas lab. He shared a preference for wire-feed technologies like WAAM and DED 3D printing over laser powder bed fusion (LPBF). Id like to have something I can put on my machining center to lay down metal and machine it, Fords prototyping specialist revealed.For Stratasys, Abro sees RAPID + TCT 2025 as a great opportunity to connect with customers. He is particularly excited by the shows location in Detroit, widely considered the birthplace of automotive manufacturing. Its a really good place to be as the automotive segment leader, he said. Sharing the F3300 step change with customers is my main goal.Abro sees the future of 3D printing in automotive expanding most on the factory floor. In particular, he believes automakers will increasingly rely on 3D printing for fixturing and tooling. Today, only 1-3% of tools are made with additive manufacturing. But we hear that number could reach 15-20%, he explained. Even a conservative 5x increase presents a huge opportunity.In the next decade, Abro expects the focus of 3D printing to shift from material development to increasing throughput. The thing that makes additive a super tool is speed, he said. If you continue to improve throughput, our position in the industry becomes much stronger for all applications.For Riha, additive manufacturing is set to become a standard part of product development, particularly for early prototypes. In his own field, Riha envisions a switch from building drivable prototypes to simulating environments where attributes are tested on tables, jigs, and fixtures. The way we test out new concepts can be improved, and using additive manufacturing allows engineers to quickly get to the result theyre looking for.Who won the 2024 3D Printing Industry Awards?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows the show floor at RAPID + TCT 2024. Photo via SME.

Schneider Electric has optimized production at its smart factory in Plovdiv, Bulgaria, by integrating the 3D printer manufacturer INTAMSYS FUNMAT PRO 310 NEO into its 3D printing operations.As a manufacturer of electrical components such as Miniature Circuit Breakers (MCBs), the company has long used additive manufacturing to enhance efficiency. But with production demands increasing, it needed a solution that could reduce lead times, improve part quality, and offer greater flexibility.Consequently in October 2024, the company introduced the 310 NEO into its 3D printing farm, bringing faster, more efficient in-house production of jigs, fixtures, and other essential parts.We prefer to use the materials produced by INTAMSYS because INTAMSUTE NEO slicing software has already built-in, optimized profiles that ensures perfect prints every single time, says Kamen Vasilski, Maintenance Engineer at Schneider Electric.How Schneider Electric streamlined manufacturingLike many manufacturers, Schneider Electric faced challenges with traditional production methods. Functional prototypes and custom components took longer to produce, leading to delays in development.Injection molding added even more time to the process, sometimes pushing lead times beyond three weeks. While 3D printing had already been in use, earlier solutions werent keeping up with the companys growing needs. Therefore, the search was on for a system that could accelerate part production without sacrificing quality.Thats where the INTAMSYS FUNMAT PRO 310 NEO came in. One of the first noticeable improvements was speed, parts that used to take 12 to 15 hours to print could now be completed in just two.The systems automatic bed leveling and a heated chamber reaching up to 100C ensured that prints maintained consistency, particularly for materials like polycarbonate (PC), which require precise temperature control to prevent warping and maintain strength. Alongside PC, the 3D printer supports a variety of engineering-grade materials, including PA6, PA12, PPA, and PPS, making it a versatile tool for the factorys production needs.Parts 3D printed with the FUNMAT PRO 310 NEO. Photo via INTAMSYS.Doubling up: faster, more versatile printing with IDEXBeyond speed, the 3D printers Independent Dual Extruder (IDEX) technology has been a key advantage. It allows for multi-material printing in a single job, opening up new possibilities for part design.One example shared by the company is a gripper used on the production line, designed with TPU95A for flexibility and PETG for structural reinforcement, ensuring components dont slip during handling. The IDEX system has also been instrumental in creating welding jigs with complex geometries by pairing PA6-CF with soluble support material SP3030, cutting production time to under six hours.Having brought the 310 NEO into its operations, Schneider Electric has seen a clear shift in efficiency. Engineers can now prototype and test jigs and fixtures faster, reducing development time and increasing flexibility.Part created with a combination of PA6-CF + SP3030. Photo via INTAMSYS.Bringing more production in-house has also helped cut outsourcing costs and improve material utilization. While the 3D printer works with an open material system, the company primarily relies on INTAMSYS filaments for their optimized print profiles and reliability.Looking ahead, Schneider Electric plans to continue expanding its 3D printing capabilities, further increasing its ability to manufacture components and spare parts on-site. This move aims to cut maintenance costs, boost self-sufficiency, and enhance industrial efficiency with additive manufacturing.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the INTAMSYS FUNMAT PRO 310 NEO 3D printer. Photo via INTAMSYS.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

United Performance Metals (UPM), a US-based specialty metals solutions provider and affiliate of ONeal Industries, has acquired Fabrisonic LLC, an Ohio-based 3D metal printing manufacturing company. The acquisition is intended to enhance UPMs manufacturing capabilities and expand its range of solutions.We are excited to welcome Fabrisonic to the United Performance Metals family. Their technology and expertise will strengthen our ability to create advanced materials and provide innovative manufacturing solutions to address the needs of our customers, said Peter Neuberger, President and CEO of United Performance Metals.Fabrisonics UAM 3D Printing Process. Photo via: FabrisonicIntegration with UPMs Specialty Processing FacilitiesFollowing the acquisition, Fabrisonic will become part of UPMs specialty processing network, which includes Precision Thin Strip in Wallingford, CT; UPM Advanced Solutions in Cincinnati, OH; and Precision Cold Saw Cutting and Grinding in Oakland, CA. These locations will continue to provide value-added processing services for specialty metals, supporting UPMs customer base.This acquisition marks an important development for Fabrisonic. Becoming part of the United Performance Metals family will allow us to utilize additional resources and capabilities, helping us extend our reach and continue delivering solutions to our customers. We appreciate the contributions of our engineers who have been instrumental in our progress, and we look forward to the next phase of our growth, said Jason Riley, General Manager of Fabrisonic.The SonicLayer 1200. Photo via Fabrisonic. Fabrisonics Metal Fabrication TechnologyFabrisonic, originally established as a division of Ohio-based engineering services provider EWI, became an independent entity in 2011. The company specializes in metal fabrication and has developed proprietary technologies to create advanced metal materials for industries such as aerospace, defense, space, and automotive.A key technology of Fabrisonic is ultrasonic additive manufacturing (UAM), a hybrid metal 3D printing process that uses ultrasonic vibrations to weld together layers of metal foils into a 3D shape. UAM is suitable for the 3D printing of integrated electronics thanks to its ability to operate at low temperatures, and also enables 3D printing at high speed.In 2021, Fabrisonic introduced its SonicLayer X Seam Welder, which the company claims is twice as powerful as other models currently available on the market. Fabrisonics patented 10,000W SonicLayer X is designed to deliver faster travel speeds, accommodate thicker materials, provide higher downforce, and offer a wider range of material choices compared to other welding models. This innovation enhances the precision and efficiency of metal fabrication, particularly in demanding industries like aerospace, defense, and automotive.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 showsFabrisonics UAM 3D Printing Process. Photo via: FabrisonicPaloma DuranPaloma 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.

Leading desktop 3D printer manufacturer Bambu Lab has released new information regarding its upcoming H2D 3D printer. The Shenzhen-based company will officially reveal the H2D on Tuesday, March 25 at 15:00 CET.Since March 18, Bambu has released daily teasers for the new system, confirming it will incorporate dual extruders and servo motors. This corroborates previous reports that the new FDM 3D printer will feature a more industrial focus than Bambus previous offerings. It is set to supersede the companys flagship X1 system, catering to prosumer users demanding cutting-edge performance.Hype beasts, vloggers and those in the influence arena have lapped up each itoa of limited detail in a frenzied marketing coup the 3D printing industry has not witnessed since the heydays of Will.I.AM extolling the virtues of warm plastic from the chilly hills of Davos in 2015.Bambu Labs H2D has been the subject of extensive industry speculation, which began to thaw when the H2Ds launch was postponed last October. Leaks and rumors suggest the 3D printer will feature Bambus largest-ever build volume (reportedly 350 x 320 x 325 mm), a new AMS system, a heated storage unit, and even an integrated laser cutter. Additionally, while the official H2D price is yet to be confirmed, many expect it will significantly exceed anything already offered by Bambu Lab. Time will tell whether these predictions are correct.Bambu Labs teaser for the Bambu Lab H2D dual extruder. Image via Bambu Lab.Bambu Labs reveals new 3D printer features Bambu Lab claims that the H2D will rethink personal manufacturing. Bambus series of teaser images include a close-up of the new 3D printers dual nozzle and a cross-section of its real servo motors. The latter will see a departure from Bambu Labs use of stepper motors in its CoreXY offerings, potentially increasing precision during high-speed 3D printing.Dual nozzle extrusion will also offer benefits over previous Bambu Lab 3D printers. For instance, it limits material waste by minimizing the filament purging requirements of Bambus single nozzle offerings. By reducing the need to switch between filaments, the H2Ds dual nozzle setup will also likely increase efficiency and speed when fabricating parts with multiple materials. This, combined with the extended build volume and servo motor integration, positions Bambu Labs new 3D printer for industrial manufacturing applications.The launch comes amid Bambu Labs growing market share within the 3D printing industry. In Q4 2023, market intelligence firm CONTEXT found that the Chinese company had outpaced all other desktop 3D printer OEMs. Bambu Lab shipped nearly 1 million units in Q4 2023, up 35% YoY in Q4 2023. That year, the firms sales grew by a staggering 3000%.This growth trend continued into 2024, as Bambu Lab cannibalized the sales of more professional-scale offerings. In Q1, global shipments of Bambu systems increased by 26%, while Midrange and Professional 3D printers fell by 7% and 34%, respectively.By Q3 2024, Bambu had again experienced market-share gains, as 24% and 8% declines were reported in the Industrial and Midrange markets, respectively. While this data highlights a pertinent trend in the shifting 3D printing Landscape, CONTEXT noted that the entry-level 3D printer market had slowed from its previous super-accelerated pace. Despite this, the report predicted that the entry-level segment would finish 2024 with a 30% YoY increase, while global midrange 3D printer shipments were set to be down by 8%.The teaser for the Bambu Lab H2Ds real servo motors. Image via Bambu Lab.New 3D FDM printer announcementsBambu Labs new 3D printer seems poised to compete with prosumer and professional 3D printers. One recent addition to this market has come from Netherlands-based 3D printer manufacturer UltiMaker. Earlier this month, the firm launched the S8, its new high-speed FDM 3D printer for industrial manufacturing. This system, which features dual extruders, boasts 500mm/s 3D print speeds and up to 50,000mm/s2 acceleration.According to Ultimaker, the 3D printer is 4x more productive than its predecessor, the UltiMaker S7. Notably, the new system, priced at around $9,000, features the companys new Cheetah motion planner. This is said to enhance motion control, elevating precision and reducing defects like ringing. It seeks to unlock high-speed fabrication without sacrificing part quality.Elsewhere, LOOP 3D, a Turkish industrial 3D printer manufacturer, recently revealed the LOOP PRO X+ TURBO. This high-speed FDM system is optimized to leverage LOOPs DYNAMIDE industrial-grade composite 3D printing filaments. Operating up to five times faster than previous models, the LOOP PRO X+ TURBO can reportedly fabricate large, complex parts in under two days. The system is also designed to minimize vibrations to optimize dimension accuracy and a consistent surface finish, making the system ideal for industrial manufacturers.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 Bambu Labs teaser for the Bambu Lab H2D dual extruder. Image via Bambu Lab.

The banishment of CNC or injection molding to join flint knives, warp-weighted looms, and other archaic tools in a cobweb-strewn museum is not happening any time soon, if ever. Additive manufacturing progress is an evolution, not a revolution. Integration, not disruption. The days of AM sweeping aside all other manufacturing technology are in the rearview mirror.I spoke with Yavuz Murtezaoglu, CEO of ModuleWorks, and Ben Weber, Head of Strategic Partnerships to find out what the 3D printing industry can learn from the CAD CAM sector, how the manufacturing landscape is changing, and to learn more about an innovation they believe could disrupt 3D printing at a magnitude similar to Bambu Labs.When seeking to understand technology adoption, there is a tendency to point to the classic hype cycle. While Gartners model has merits, it is not without flaws. Not all technology follows a hype path, furthermore, progress can be non-linear. For example, 3D printing has seen gradual and steady adoption in several key vertical markets it is not a coincidence that these markets are tightly regulated and safety-conscious. Learning from history is perhaps a better way to understand 3D printings trajectory.ModuleWorks, a German software developer, has over two decades of experience pushing code that optimizes CAD/CAM and CNC software. People say were the best kept secret in manufacturing, Yavuz Murtezaoglu, Founder and CEO, tells me. The algorithms developed by some of the companys 400 employees are now licensed by 90% of CAM companies.Yavuz Murtezaoglu, CEO of ModuleWorks. Photo via ModuleWorks. Job Shops and GeopoliticsThe adoption of additive manufacturing has been slow due to the conservatism of traditional manufacturers. Most job shops and large-scale manufacturers operate on long planning cycles. Theyve optimized their processes over decades, and unless theres a massive pain point, they have little incentive to change, says Ben Weber.Unlike software-driven industries, where disruption is rapid, manufacturing is slow-moving. A job shop may invest tens of millions in CNC machining, making change costly and risky. Smaller manufacturers, though more flexible, are often operator-driven and may be hesitant to experiment. ModuleWorks believes additive will integrate into conventional workflows rather than replace them. Will job shops add 3D printers alongside CNC machines, or will dedicated additive job shops emerge? asks the CEO.Supply chain complexities and workforce training requirements compound manufacturing inertia. While more prominent manufacturers may invest in research, smaller firms often lack the resources to experiment with new technologies. The long-term challenge remains demonstrating that additive can enhance productivity without disrupting established workflows.So, what does this mean for the future of additive manufacturing? Its debatable whether early industry messaging aided adoption. The idea of a 3D printer in every home was never realistic, and what manufacturer wants to hear their industry is about to be disrupted? Additive must integrate into existing processes rather than stand alone.The replicator concept, a machine that can make anything, may paradoxically have slowed adoption by offering up a vast number of potential applications. In CAD/CAM, software evolved around specific industries: mold and die, turbine blades, and production parts. Each had a defined need and clear ROI, explains Weber. Additive, by contrast, remains fragmented.Ben Weber, Head of Strategic Partnerships. Photo via ModuleWorks. Bringing Multi-Axis 3D Printing to the Masses3D printing is just one step in a chain. Something happens before you print, and something happens after you print. Unless additive fits into that workflow, adoption will remain limited. ModuleWorks five-axis ironing tool is one example of bridging this gap. The ability to print support-free structures is another critical milestone. ModuleWorks additive toolpath generation algorithms enable five-axis printing, reducing the need for material waste and post-processing. These approaches could make the technology more viable for industrial use, where precision and efficiency are critical.The limitations of conventional fused deposition modeling (FDM) 3D printing are well known: parts with shallow curves expose layer lines, and complex geometries require support structures that add material waste and post-processing effort. ModuleWorks has developed algorithms to address both issues. If we can bring this to market and democratize it, it could have an impact similar to what Bambu Lab has achieved in next-generation 3D printing, says Yavuz Murtezaoglu.The key lies in multi-axis control. Standard FDM 3D printers move in three linear axes, but ModuleWorks approach tilts the print bed, allowing for smoother surfaces and support-free printing. The innovation is embedded in an algorithm Murtezaoglu developed during his PhD research, which systematically decomposes complex geometries into optimally printable segments. The PhD thesis explains how to eliminate support structures and improve the stair-stepping effect caused by layer-by-layer printing, he explains.ModuleWorks printbed 3D printing on a RatRig. Photo via ModuleWorks.Open Hardware, Proprietary SoftwareWhile the hardware modifications required to introduce tilt are open-source, the software remains proprietary. The printers are open source, and the changes we apply will naturally be open too, says Murtezaoglu. But the software is not open sourceits open to everyone under non-discriminatory licensing conditions.However, one of the most significant barriers to adoption is convincing printer manufacturers to integrate the technology. The 3D printing industry primarily focuses on selling high volumes of machines rather than developing complex multi-axis systems. Its like the COVID vaccine marketthese companies are narrowly focused on shipping units rather than considering whats possible, says Weber. The challenge was always convincing them that our algorithms could transform their machines.ModuleWorks engineered a workaround to bypass hardware inertia: modifying existing printers to introduce limited tilt. At Formnext 2024, the company showcased a RatRig printer with extended parts that allowed for up to 20 degrees of tilt, with future iterations targeting 30 degrees. You dont need to tilt 90 degrees to solve most problems, Murtezaoglu explains. Even a 20-degree tilt lets the algorithm adjust the toolpath to print around corners, reducing the need for supports.A pump housing with complex overhangs printed without supports. Image via ModuleWorks.Lessons from the CAD / CAM worldThe evolution of toolpath software in CNC machining offers a roadmap for additive manufacturing. Yet, the latter has yet to embrace the efficiencies that took decades to refine in subtractive manufacturing.Over the past 40 years, CNC machining has driven demand for increasingly sophisticated toolpath software, accommodating developments such as five-axis milling and multi-tasking machines. Similarly, AM is now pushing software requirements forward with new processes like Wire Arc Additive Manufacturing (WAAM) and Directed Energy Deposition (DED), often integrating robotics. However, unlike CNC, where independent CAM software solutions dominate, AM machines typically ship with proprietary software. This fragmentation limits demand for cross-compatible CAM software.Another stark contrast is in workforce expectations. In CNC, manufacturers have long accepted the necessity of trained CAM programmers who specialize in toolpath generation, with an estimated two million professionals working in the field. In AM, some expect to push a button and get a part printed, making adjustments only for process parameters such as heat management. While this may suffice for entry-level applications, industrial-scale AM requires more expertise; among specialists this is now acknowledged.Software development in AM also follows a familiar but inefficient trajectory. In the CNC industry, companies eventually adopted shared software components for CAD design, data translation, and toolpath simulation, reducing redundant R&D efforts. In AM, many software vendors are still attempting to build everything in-house, slowing progress.Whether AM will consolidate as the CNC market did remains uncertain. The CNC industry has seen major consolidations, with firms like Hexagon and Sandvik acquiring multiple CAM software companies. AM, by contrast, remains fragmented, with a hazy path toward similar mergers. Until AM software becomes as standardized as its CNC counterpart, its growth will likely remain constrained.Manufacturing in a Shifting Geopolitical LandscapeManufacturing is increasingly shaped by geopolitics as countries seek to localize production. If products must now be produced domestically in high-wage countries, automation becomes essential, says Murtezaoglu. You cant match low-cost labor, so you must reduce costs through better algorithms.The push for domestic manufacturing may accelerate its adoption in industries requiring rapid, localized production as space and defense firms invest in on-demand production capability to reduce supply chain vulnerabilities.While mass adoption remains uncertain, ModuleWorks is positioning itself for an eventual shift. If job shops start adding robots and large-format 3D printers, theyll want to use familiar software like Siemens NX or Mastercam, says Murtezaoglu. We already have 90% of those shops using our software for CNC machining. The moment they activate our additive component, they can run their new equipment immediately.Emerging markets for the technology include mobile, on-demand repair applications, such as railway maintenance and, in some minds, battlefield repairs. If a customer needs a sophisticated additive solution and theres no existing answer, we can deploy 20 developers, deliver in three months, and ship a fully operational system, Murtezaoglu explains.ModuleWorks is prepared for when the industry catches up. Were building up our muscles up in the gym, Murtezaoglu quips. When the shift happens, the company intends to be at the forefront, providing the software infrastructure that will finally integrate additive manufacturing into mainstream production.For ModuleWorks, the focus is on enabling manufacturers to adapt rather than forcing radical change. Its about making the transition as seamless as possible, Weber says. When the industry is ready, well be right there.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows 3D printing complex overhangs. Photo via ModuleWorks.

German multinational engineering and technology company Bosch has launched a new metal additive manufacturing facility at its Nuremberg plant, investing nearly 6 million.At the heart of the facility is a Nikon SLM Solutions NXG XII 600 metal 3D printer, which the company says will play a key role in producing complex metal parts more efficiently. With this addition, the automotive giant sees itself as the first Tier-1 automotive supplier in Europe to operate a facility in this performance class.The new setup is part of Boschs ongoing effort to strengthen its manufacturing capabilities in Germany. At full capacity, the new facility can manufacture up to 10,000 kilograms of metal parts annually, with production speeds reaching 1,000 cm/h.According to Technical Plant Manager Jrg Luntz, the main goal is to reduce time-to-market by moving faster than traditional manufacturing methods allow. Even today, only a few companies can produce technology on an industrial scale the way Bosch does. Were now going one step further, taking volume production in metal 3D printing to the automotive level.3D printed steering gear box. Photo via Bosch.Flexible production and faster turnaround timesOne of the benefits of the new system is its flexibility. The printer can produce unfinished parts directly from digital files, eliminating the need for tooling. It also minimizes raw material waste, which Weichsel pointed out contributes to more sustainable production practices. In addition, the setup allows Bosch to adapt quickly to changes in batch size while keeping the entire process in-house.The machine is capable of producing a wide range of parts, from components used in hydrogen applications and electric vehicle motor housings to e-axle parts and engine blocks for racing. Using twelve lasers, the printer fuses metal powder layer by layer according to computer-aided design files.Compared to earlier systems, it operates up to five times faster and can handle geometries that would be challenging, or even impossible, with traditional milling. For example, the ability to print curved or internal channels offers clear advantages for complex component design.Bosch remains committed to Germany as an industrial location and is investing large sums of money here. By introducing new technologies in our plants, we are securing considerable sales potential, said Klaus Mder, member of the Bosch Mobility sector board responsible for operations.A case in point is engine block manufacturing. Traditionally, this process can stretch over three years, with mold-making alone requiring up to 18 months. With 3D printing, Bosch can bypass that step entirely. The design data goes straight to the machine, and a finished engine block can be produced in just a few days, a shift that significantly shortens the development timeline.At the plant level, expectations are high. Alexander Weichsel, Commercial Plant Manager in Nuremberg, noted that the facility is designed to make metal part production both faster and more productive, factors he believes will enhance Boschs competitiveness.Beyond automotive, the company also sees opportunities in areas such as energy and aviation.New Nikon SLM Solutions NXG XII 600 3D printer at Nuremberg plant. Photo via Bosch.Metal AM advantage in automotive sectorMetal 3D printing is increasingly being used in automotive production to streamline workflows, reduce costs, and enable complex part designs not possible with traditional methods.Earlier this month it was announced that Japanese automotive manufacturer Honda is exploring how laser powder bed fusion (LPBF) 3D printing could enhance manufacturing across its automotive, motorsports, aerospace, and wheelchair racing divisions. The company highlighted benefits such as faster production, lower costs, and shorter lead times.According to the company, metal 3D printing is already part of its workflow, with LPBF systems from Nikon SLM Solutions used to create complex components like pistons and turbine housings for Oracle Red Bull Racings F1 cars, as well as lightweight, custom-fit aluminum handlebars for racing wheelchairs. Simulation tools and real-time monitoring further improved part accuracy and overall manufacturing precision.Back in 2023, Europes largest carmaker Volkswagen Group acquired a second MetalFAB 3D printer from Netherlands-based Additive Industries to expand its metal additive manufacturing capabilities. The company cited the systems automation, modularity, and efficiency-enhancing tools as key factors in the decision.Its first MetalFAB unit had already contributed to significant cost and lead time reductions. Back in 2018, Volkswagen opened a dedicated 3D printing center, and more recently, partnered with HP and Siemens to further scale production. At its Wolfsburg plant, the company aimed to manufacture up to 100,000 3D printed automotive components annually by 2025.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows 3D printed steering gear box. Photo via Bosch.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

Reinforce 3D, the Spanish developer of structural reinforcement solutions for additive manufacturing, has secured a $1.2 million capital investment to advance its Continuous Fiber Injection Process (CFIP) technology. This funding aims to accelerate the companys growth and expand its innovative technology applications by 2025.The investment round was led by prominent venture capital firms focused on industrial innovation and advanced manufacturing. Reinforce 3D plans to utilize the funds to scale up production, refine its proprietary reinforcement technology, and enhance market penetration across key industries, including aerospace, automotive, and defense.Stock of fibers used in production. Photo via Reinforce 3DAdvancing Structural Reinforcement in Additive ManufacturingReinforce 3D has developed a process that enhances the mechanical properties of 3D printed parts by integrating advanced fiber reinforcement techniques. This method significantly improves the strength, durability, and reliability of printed components, addressing a critical challenge in additive manufacturing.At the core of this advancement is Reinforce 3Ds Continuous Fiber Injection Process (CFIP) technology. CFIP enables in-situ reinforcement of 3D-printed polymer parts with continuous fibers, enhancing their mechanical properties without requiring post-processing steps. By embedding reinforcement fibers directly during the printing process, CFIP ensures superior structural integrity compared to traditional composite manufacturing techniques.The companys technology is particularly valuable for industries requiring high-performance materials, such as aerospace and automotive, where lightweight yet durable components are crucial. By reinforcing printed parts during the manufacturing process, Reinforce 3D provides technology that rivals traditional composite manufacturing techniques.Strategic Growth and Industry ExpansionBlanca Garro, Reinforce 3Ds CEO, expressed enthusiasm about the investment, emphasizing the potential impact of their technology on the broader additive manufacturing sector. We are ready to scale faster, innovate more, and create lasting value for our customers and partners. This round of investment marks the beginning of an exciting new chapter for us. We are immensely grateful to our investors for their confidence in our vision of creating a more innovative, efficient, and sustainable future. Their support inspires us to reach new heights.The company recently announced a strategic partnership with Spring Srl, a leader in advanced composite manufacturing. This collaboration aims to further refine CFIP technology and expand its applications across various industrial sectors, strengthening Reinforce 3Ds position as a key player in the additive manufacturing landscape.Delta Machine for 3D printing reinforcement. Photo via Reinforce 3D.Reinforcement Technology in Additive ManufacturingWhile CFIP represents a breakthrough in fiber reinforcement for additive manufacturing, other companies have also developed advanced techniques to enhance the strength and durability of 3D-printed components.Markforgeds Continuous Fiber Reinforcement (CFR) technology integrates continuous fibers such as carbon fiber, fiberglass, or Kevlar into polymer matrices during the printing process. This approach produces composite parts that are significantly stronger and stiffer than traditional thermoplastic 3D prints.Anisoprints Composite Fiber Co-extrusion (CFC) technology enables the simultaneous deposition of continuous fibers and thermoplastics, allowing precise control over fiber orientation. The process is particularly beneficial for applications requiring optimized load distribution, such as robotics and structural components in automotive manufacturing, where both strength and flexibility are crucial.Continuous Composites CF3D process combines continuous fiber reinforcements with thermosetting resins using a robotic deposition system. CF3D employs snap-curing thermosetting resins to create near-instant solidification, allowing the fabrication of highly anisotropic composite parts with superior strength-to-weight ratios.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 CFIP Technology showcased through a tubular cavity. Photo via Reinforce 3D.

Creaform-backed portable 3D scanner manufacturer Peel 3D has launched Peel.CAD Pro, a 3D scanning manipulation software designed to simplify professional reverse engineering workflows.Built specifically for use with Peel 3 3D scanners, the software is meant to help users convert scan data into CAD-ready models with fewer steps and less friction. It now sits alongside the companys existing offerings, Peel.OS and Peel.CAD, as part of a growing ecosystem of 3D scanning tools.Coinciding with the software release, Peel 3D has also rolled out a revised pricing structure. The Peel 3 scanner bundled with Peel.OS is available online for $5,990. A package that includes the scanner and Peel.CAD is priced at $8,990. The most comprehensive option, combining the Peel 3 scanner with the new Peel.CAD Pro software, is set at $11,990.Peel.CAD Pro is a game-changer for in-demand companies that want to harness 3D scanning processes for their reverse engineering projects, said Pierre-Luc Delagrave, Product Manager at Creaform. Peel.CAD Pro makes it easy for users to generate usable and accurate CAD models right after 3D scanning, saving substantial time and effort.A person using the Peel 3 3D scanner to scan an interior car door panel on a table next to a laptop displaying the scanned data in real time. Photo via Peel 3D.Whats new in Peel.CAD Pro?According to the company, Peel.CAD Pro is aimed at businesses and experienced consumers who need to reverse engineer relatively simple parts, whether for product design, tuning, MRO work, or broader engineering tasks.What makes the software stand out is how accessible it is, even for users with limited background in 3D scanning or CAD. Its designed to handle a wide range of shapes and sizes, and the setup is intended to reduce the learning curve typically associated with reverse engineering.Under the hood, the software offers several tools to help users move from scan to CAD with more ease. Features include mesh extraction algorithms, alignment controls, sketching tools, and solid modeling capabilities.Theres also a real-time analysis function, which lets users compare their 3D models with the original scan data as they work, an added layer of feedback that can help with precision.Those working in SolidWorks may find the direct integration particularly useful. This feature from Peel.CAD Pro allows users to transfer design history and timeline operations straight into SolidWorks, which could help eliminate the need to jump between programs and rebuild features manually.More details about Peel.CAD Pro, its capabilities, and the updated product bundles are available on the companys website at www.peel-3d.com.A screenshot of a scan of a casting 3-in-2 pipe within the Peel.CAD Pro platform. Image via Peel 3D.Refining scan data through specialized softwareCapturing a scan is only half the job, processing that data into something usable is where dedicated software makes all the difference.With this in mind, 3D scanner manufacturer Thor3D released version 3.3 of its scan processing software, Calibry Nest, in 2020. This update introduced support for the Calibry Mini 3D scanner, along with faster texturizing, enhanced scan manipulation tools, and a redesigned user interface.Designed to serve as a bridge between Thor3Ds scanners and users computers, Calibry Nest allows users to process and finalize 3D scans for printing. New features include a Curvature Selection tool, an upgraded model dissection system, and performance improvements to functions like Cut on Frames and texture mapping.At the same time, 3D printer OEM 3D Systems announced two novel versions of its Geomagic Design X and Geomagic Wrap 3D scan processing software, aimed at helping engineers streamline their workflows and produce high-precision products from scan data more efficiently.As a part of the package, Geomagic Design X 2020 introduced features like Unroll/Reroll, which allowed users to unwrap a 3D mesh into a 2D sketch and then rewrap it, improving accuracy in modeling revolved parts. It also included Selective Surfacing to support hybrid CAD modeling. Meanwhile, Geomagic Wrap 2021 added scripting automation, a Python-based editor, improved texture map tools, and HD Mesh Construction for filling in gaps in point cloud data.Later in 2024, 3D Systems sold its Geomagic portfolio to Hexagons Manufacturing Intelligence Division for $123 million, with the transaction expected to close in the first half of 2025 (H1 2025) following customary regulatory reviews.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows a person using the Peel 3 3D scanner to scan an interior car door panel on a table next to a laptop displaying the scanned data in real time. Photo via Peel 3D.

French 3D printer developer Prodways Machines is introducing the DENTAL PRO Automated Line, a system designed to bring full automation to dental laboratories and aligner manufacturers.The company will showcase it at the International Dental Show (IDS) 2025 in Cologne from March 25-29. Built for continuous, hands-free production, the system aims to make workflows smoother and more efficient while reducing the need for manual intervention.Prodways describes the DENTAL PRO Automated Line as a fully automated industrial 3D printing solution specifically designed for dental applications. The company emphasizes that the system has undergone extensive research and testing to ensure reliability.By combining automation with high-precision 3D printing, it aims to increase efficiency, lower labor costs, and streamline workflow management for dental labs looking to expand their operations.The Dental Pro Automated Lines represent a major leap forward in production efficiency for dental laboratories, says Vincent Icart, CTO-COO of Prodways Machines. By integrating advanced 3D printing with automated platform handling, we are eliminating bottlenecks and maximizing throughput, allowing labs to focus on precision, quality, and scalability rather than manual operations.DENTAL PRO 200 Automated Line. Image via Prodways.High-throughput dental productionAt the core of the system is a rotating four-tray setup that keeps production running with minimal oversight. Designed for high-throughput manufacturing, it ensures consistent, repeatable results with each cycle. The automated loading and unloading mechanism allows for zero-touch production, so technicians can focus on other tasks rather than manually handling prints.According to Prodways, the system can produce up to 220 aligner models in just four hours, offering a faster and more reliable alternative to traditional workflows. Real-time monitoring and remote access give laboratories full control over production while reducing errors and inefficiencies.The DENTAL PRO Automated Line builds on the companys Dental Pro 3D Printer Range, integrating automated platform handling with Prodways MOVINGLight Digital Light Processing (DLP) technology. This setup allows for non-stop production, making it a suitable choice for labs looking to scale up without sacrificing quality.To ensure precision, the system prints at a 42m per pixel resolution, allowing for highly detailed models. The automatic loader keeps production moving without operator intervention, while the 300 x 445 mm build platform supports batch production of multiple models at once.Each cycle can produce 72 denture bases or 55 aligner models, making it a flexible option for labs of all sizes. With real-time monitoring and remote access, users can keep track of production from anywhere.Automation in dental 3D printingAs automation continues to reshape dental 3D printing, other industry players are also introducing solutions aimed at improving efficiency and scalability.Recently, it was announced that Carbon is set to introduce automation-driven solutions to improve dental lab efficiency. at IDS 2025. New features in the Automatic Operation (AO) Suite and the unveiling of Lucentra, a system for clear aligner production, will take center stage.Designed to streamline workflow, the AO Suite includes tools like AO Backpack, Automatic Print Preparation (APP), Parts Retrieval Basket, and AO Polishing Cassette, reducing manual effort in pre-print, post-print, and polishing processes. Additionally, Lucentra enhances aligner production by delivering smoother printed models for improved clarity. These developments are expected to support scalable, high-throughput dental manufacturing while maintaining precision and efficiency.Lucentra solution. Photo via: CarbonA few days back, automated, all-in-one chairside 3D printing specialist Zylo3D and CAD-Ray partnered to introduce a streamlined 3D printing solution for dental professionals, combining Zylo3Ds AI-driven automation with CAD-Rays expertise in digital scanning and affordability. By simplifying the production of dental restorations, nightguards, and models, the system removes many of the challenges associated with traditional 3D printing workflows.According to the company, the automated processes reduce manual effort, while the cost-effective scanning technology makes advanced digital dentistry more accessible. With a focus on efficiency and precision, the collaboration aims to help professionals integrate high-quality 3D printing into their practices with fewer barriers and a more seamless workflow.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows DENTAL PRO 200 Automated Line. Image via Prodways.

Sculpteo, the France-based digital manufacturing company and subsidiary of BASF, has introduced PA12 Blue, a new 3D printing material designed specifically for food handling, preparation and storage. This material complies with key regulations such as the European Unions (EU) food safety directives and the U.S. Food and Drug Administration (FDA) guidelines, making it applicable across other industries with stringent safety regulations.Founded in 2009, Sculpteo offers on-demand 3D printing services to businesses worldwide. The company provides a wide range of materials and technologies, including Selective Laser Sintering (SLS), Multi Jet Fusion (MJF), and Stereolithography (SLA). In 2019, Sculpteo wasacquired by BASF, further strengthening its material innovation capabilities and expanding its market reach.PA12 Blue 3D-printed components. Photo via Sculpteo.Expanding Applications of PA12 BluePA12 Blue builds upon the widely used PA12 (Nylon 12), a material known for its excellent mechanical properties, durability, and resistance to chemicals and wear. PA12 has been a staple in additive manufacturing for applications requiring high-performance thermoplastics, including aerospace and automotive components. By introducing PA12 Blue, Sculpteo expands the capabilities of this material into food-safe applications. The material is highlighted by its mechanical performance, chemical resistance, and durability. These properties make it ideal for producing custom food processing tools, machinery parts, safety equipment, and kitchen utensils. The blue color is deliberately chosen, as blue is rarely found in natural foods, making it easier to detect foreign objects and reduce contamination risks.The material is versatile in the 3D printing industry, as it allows for rapid prototyping as well as finished consumer products. It has a high abrasion resistance and good UV resistance, which is ideal for highly demanding environments. The biocompatibility of this 3D printing material allows it to 3D print objects for medical and pharmaceutical applications, such as 3D printed prostheses.PA12 Blue is printed using SLS and its available in two formats, rough and smooth. The smoother finish is achieved through a chemical process that reduces the porosity of the material making it waterproof and easier to clean.Technical Benefits and Industry AdoptionSculpteos introduction of PA12 Blue aligns with a growing trend of incorporating 3D printing in the food industry, where rapid prototyping and on-demand manufacturing are becoming crucial for efficiency. With the increasing adoption of additive manufacturing in industrial sectors, the availability of certified food-safe materials expands the potential applications of 3D printing in commercial food production.As regulatory compliance remains a critical factor in food-related industries, materials like PA12 Blue could pave the way for wider adoption of 3D printing in food manufacturing and packaging solutions. Companies seeking to innovate in hygiene-sensitive environments may benefit from the flexibility and cost savings that Sculpteos new offering provides.Hygiene and Safety in Additive ManufacturingThe role of 3D printing in food safety has gained more relevance as industries seek innovative solutions for hygienic and regulatory-compliant manufacturing. ERIKS, an international industrial equipment supplier, has demonstrated how Ultimaker S5 3D printers can be leveraged to produce food-safe components, ensuring compliance with strict food safety standards. By using certified filaments and rigorous quality control measures, ERIKS has successfully integrated additive manufacturing into environments where contamination risks must be minimized.Meanwhile, researchers at the Hong Kong University of Science and Technology (HKUST) have developed a method of 3D printing which 3D prints and cooks food simultaneously. This system employs artificial intelligence (AI) and graphene based infrared heating to improve precision, efficiency and safety in the food printing process. The infrared-treated samples showed significantly reduced bacterial growth compared with traditional cooking methods.The importance of high sanitary standards in additive manufacturing has also been demonstrated in the medical sector. Similar to food production, the medical field demands precise material properties that prevent contamination and ensure compliance with industry safety regulations. Mass customization has transformed hygiene-sensitive industries, including healthcare and food production by leveraging industrial-grade 3D printing materials to manufacture made-to-fit medical devices, ensuring biocompatibility and regulatory compliance. Through its collaboration with Twikit, a digital manufacturing software company specializing in mass customization workflows Sculpteo demonstrates how advanced 3D scanning and customization workflows enable manufacturers to meet strict regulatory standards while maintaining cost efficiency.As 3D printing technologies continue to evolve, their applications in food safety and production efficiency are expected to expand, providing manufacturers with new ways to optimize processes while ensuring compliance with industry regulations.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 Sculpteo PA material in blue. Photo via Sculpteo.Rodolfo HernandezRodolfo Hernndez is a writer and technical specialist with a background in electronics engineering and a deep interest in additive manufacturing. Rodolfo is most interested in the science behind technologies and how they are integrated into society.

3D printer manufacturer Prusa Research has unveiled Prusa EasyPrint, a web-basedapplication designed to simplify 3D printing by enabling users to slice models directly from their phones, tablets and laptops, enhancing accessibility for beginners in 3D printing.Prusa EasyPrint aims to bypass some of the traditional processes for 3D model printing preparation, such as configuring printer profiles and fine-tuning specific settings. As a browser-based solution, users can easily look for models on Printables, access a 3D preview with a single click, and let the application automatically detect connected printers via PrusaConnect. The system applies the appropriate slicing profiles before printing.Prusa Easy Print UI. Photo via Prusa Research.Features and how to access Prusa EasyPrintThe application features additional functions such as material status assessment and printer readiness verification, further streamline the process. Once a user starts a print, the app sends the model to PrusaSlicer, which runs on cloud servers. Finally, the G-code is generated and sent to the printer.PrusaSlicer-derived, or forked, slicers such as Orca and BambuStudio are compatible since the app runs the slicers on the back-end. This suggests potential future support for non-Prusa 3D users.Users can also use the cloud slicer interface for offline printers, by manually downloading and adding the G-code for transfer via USB or SD Card.Josef Pra has addressed concerns regarding forced cloud dependency. He emphasized that EasyPrint is an optional tool, and technically, not a slicer itself. Instead, its a web application that generates 3MF files, which are compatible with modern slicers.The decision to use cloud-based slicing is primarily driven by the memory and processing constraints of mobile devices. Data security in 3D printing is one of Prusas key priorities, making cloud-based slicing a secure and efficient solution rather than a restriction.Currently, EasyPrint has some limitations, such as support for only one job at time and restrictions on model size and detail. Prusa Research plans to improve these aspects while also introducing more features, such as cloud storage and sharing.Early access is available via an invite-base system. Users who have already received access can invite a limited number of others. Additionally, a form was shared for 100 more users to join, with Printables handlesCloud Integration in 3D PrintingCloud-based slicing and remote management tools are being integrated in various 3D printing ecosystems. Services like Prusa Connect and RaiseCloud provide printer monitoring and job management, while platforms such as OctoPrint offer open-source remote printing solutions. Other manufacturers, like UltiMaker, have also developed cloud-integrated solutions for print preparation and device coordination. Platforms like 3DPrinterOS offer offline 3D printing capabilities, allowing users to prepare, slice, and manage print jobs without an internet connection, thereby addressing concerns related to offline access.Discussions around data security, offline access, and user control remain pertinent. For instance, in July 2021, the U.S. Department of Defense (DoD) Inspector General released a report highlighting significant cybersecurity risks associated with 3D printing technologies.The audit revealed that these systems were often misclassified as mere tools rather than information technology assets, leading to inadequate implementation of cybersecurity controls. This oversight exposed critical design data to potential unauthorized access and manipulation, posing risks to both the integrity of 3D-printed components and the broader DoD Information Network.Other concerns regarding access to 3D printers and dependence on cloud-based applications have arisen. While cloud integration enhances accessibility and remote monitoring, it also raises issues of operational reliability and user autonomy. For example, Bambu Labs recent authentication update sparked controversy by introducing a proprietary mechanism that some users feared could restrict third-party tools and materials. Although the company defended the update as a security enhancement, critics raised concerns about vendor lock-in and potential limitations on independent modifications. This incident highlights the ongoing debate between security, cloud connectivity, and the importance of maintaining offline functionality and user control in 3D printing.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.The Prusa EasyPrint software. Photo via Prusa Research.

Fraunhofer Institute for Ceramic Technologies and Systems (IKTS) spin-off AMAREA Technology has installed an MMJ ProX 3D printing machine at the institute, further expanding its work in Multi Material Jetting (MMJ) technology.This addition expands the institutes research capabilities in additive and hybrid manufacturing, particularly with ceramic materials, reinforcing its role in developing multi-material printing applications. For those interested in the specifics, the system operates with droplet volumes ranging from 0.5 to 50.0 nanoliters (nl), droplet diameters from 200 m to over 1,000 m, and layer thicknesses between 70 and 300 m.We are pleased that Fraunhofer IKTS is among the first customers to utilize our system for the development of novel products, thereby expanding the market for Multi-Material applications, says Steven Weingarten, developer of MMJ technology and co-managing partner of AMAREA Technology.MMJ ProX next-generation Multi-Material 3D printing machine. Image via AMAREA Technology.Precision multi-material printing for complex componentsThe MMJ ProX system comes with a build volume of 530 x 300 x 200 mm, making it suitable for both small and large-scale complex components. Unlike conventional methods that require extensive effort for tailored material properties, this system enables precise control over hardness, flexibility, conductivity, and chemical resistance.By combining different materials within a single print job, manufacturers and researchers can create parts with custom properties, from UV-resistant and structurally robust components to fine-tuned aesthetic and tactile finishes.One of the key advantages of the MMJ ProX series is its modular design, which offers various configuration options based on industrial and scientific needs. The version installed at Fraunhofer IKTS is equipped with six printheads, enabling simultaneous processing of up to six different materials.This capability opens up a wide range of applications across aerospace, electronics, mechanical engineering, energy, and medical sectors. It also presents opportunities in more specialized fields such as additive manufacturing for jewelry and watchmaking.At the core of MMJ technology is its ability to deposit particle-filled thermoplastic materials in droplet form with extreme precision. Material is placed only where needed, ensuring efficient fusion and layer formation within fractions of a second.This method not only reduces post-processing but also improves material utilization. Additionally, monomaterials can be re-melted and reused, while the printing material remains stable for long-term storage, making the process both practical and sustainable.According to the spin-off, the MMJ ProX system is designed for accuracy and efficiency, allowing users to fine-tune porosity or create fully dense structures depending on application needs. Rapid cooling ensures instant solidification, contributing to dimensional stability. The machine is also compatible with a wide range of material classes, making it adaptable to different production requirements.Successful handover of the MMJ ProX 3D printing machine at Fraunhofer IKTS from AMAREA Technology CEO Steven Weingarten to Lisa Gottlieb, Research Associate at Fraunhofer IKTS. Photo via AMAREA Technology.Expanding applications of multi-material 3D printingBuilding on its suitability, multi-material 3D printing has been used in various applications including the likes of dental and medical.For example, US-based 3D printer OEM 3D Systems launched a multi-material 3D printed denture solution, introducing what it described as the industrys first jetted, monolithic denture offering. The system utilizes two distinct materials, NextDent Jet Denture Teeth for rigidity and aesthetics, and NextDent Jet Denture Base for flexibility and impact resistance.Designed for high-volume production, the solution combines high-speed jetting technology with monolithic 3D printing to accelerate manufacturing. With this approach, the solution allows for improved accuracy, repeatability, and a lower total cost of operation for dental labs and practitioners.Another notable contribution came from Finnish bioprinting firm Brinter introducing what it described as the worlds first multi-material, multi-fluidic bioprinting printhead, expanding possibilities in tissue engineering and regenerative medicine. Designed for use with its own 3D bioprinters, the system underwent pilot testing with select research institutions and pharmaceutical companies.Extensive material capabilities of the printhead allowed for higher-precision applications, including tissue repair and localized disease treatments. With support for up to 4,096 material combinations in a single build, the printhead aimed to eliminate the need for multiple tools when processing granulates, pastes, and liquids.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows successful handover of the MMJ ProX 3D printing machine at Fraunhofer IKTS from AMAREA Technology CEO Steven Weingarten to Lisa Gottlieb, Research Associate at Fraunhofer IKTS. Photo via AMAREA Technology.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

Post-processing systems manufacturer PostProcess Technologies has introduced the DEMI X 520 for Dental PolyJet, a system designed specifically for dental laboratories utilizing PolyJet 3D printing.Although the price is undisclosed, this system is developed as an extension of the DEMI X 520 platform to address post-processing challenges in dental manufacturing by automating the removal of support material. Having integrated proprietary chemistries, and intelligent software, the DEMI X 520 for Dental PolyJet is designed to improve workflow efficiency, reduce manual intervention, and ensure consistent results.As a dental lab utilizing PolyJet technology, we are always looking for solutions that enable us to be more efficient without compromising quality, said Olivier Mangot, Co-Director of Ninety!, a dental production centre located in Saint-Etienne, France. I am no longer dependent on an operator. With this solution, I can clean 20 times more parts than before and get incredibly high-quality results.The DEMI X 520 for Dental PolyJet system. Image via PostProcess Technologies.Improved support removal for enhanced dental efficiencyAt the core of the system is PostProcess Axial Flow Technology, which combines controlled variable pump speed and pre-set software controls to ensure uniform results.This approach is aimed at addressing a common challenge in dental 3D printing, efficiently removing support material without compromising part quality. Instead of relying on time-consuming manual processes, dental labs can integrate this system into their workflow to improve productivity while maintaining accuracy and repeatability.To further enhance automation, PostProcess has integrated its AUTOMAT3D platform, allowing users to customize post-processing steps, store processing parameters, and standardize workflows.The one-touch operation feature simplifies support removal, making it easier for labs to manage production without constant oversight. Combined with the companys specially formulated chemistries, the system ensures thorough support removal while preserving the integrity of printed parts.At PostProcess Technologies, were committed to delivering innovative, safe, and efficient solutions that empower dental labs to meet the demands of todays rapidly evolving additive manufacturing market, said Jeff Mize, CEO of PostProcess Technologies.For dental labs handling high volumes of PolyJet-printed components, the DEMI X 520 is designed as a turnkey solution to eliminate manual bottlenecks and increase efficiency.By automating a traditionally labor-intensive process, labs can focus more on production and quality control rather than post-processing work. The system also aims to reduce overall labor costs, offering a streamlined alternative to manual support removal.The DEMI X 520 for Dental PolyJet reflects that commitment by providing an application specific production system that simplifies and automates the post-printing workflow, maximizing lab productivity and Safety, added the CEO.A 3D printed biocompatible dental part. Photo via PostProcess Technologies.Technical specifications and pricingCustomers interested in pricing details for the DEMI X 520 for Dental PolyJet system can contact the company here.Electrical RequirementsUS | 120 Volt, 60Hz, 3-Phase, EU | 230 Volt, 50 Hz, 3-PhaseEnvelope Capacity (L X W X H)14 x 14 x 15 (36 x 36 x 39 cm)Lift Capacity10 lbs (4.5 kg)Consumable UsedPLM-101-SUBConsumable Capacity24 gallons (91 liters)Machine Dimensions(W x D x H)Doors Closed: 32 L x 25 W x 67 H (82 x 64 x 170 cm),Doors Open: 54.6 L x 28.9 W x 67.8 H (139 x 73 x 172 cm)System WeightEmpty: Approx. 325 lbs (147 kg),Full: Approx. 525 lbs (238 kg)System Warranty12 months on-site service and support, as per PostProcess Technologies conditions of sale.Environmental RequirementsTemperature range: 60-80F (15-27C),Relative humidity: 0-80%SoftwareAUTOMAT3D, Windows 10Regulatory ConformityCE, SGSFeatures & OptionsCustomizable settings with recipe storage capability / Ability to clean parts and trays simultaneously on or off platformSafety FeaturesEmergency stop / Safety enclosure with door sensorConnectivityUSB Port: USB 3.1,Ethernet: Fully compliant with IEE 802.3, IEEE 802.3u, IEEE 802.3abMaterial CompatibilityEffectively removes SUP7111, SUP705, SUP706, SUP710 support materialPrinter CompatibilityStratasys J3 DentaJet, J5 DentaJet, DentaJet XLWhat3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the DEMI X 520 for Dental PolyJet system. Image via PostProcess Technologies.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

At TCT Asia 2025, China-based manufacturer Farsoon showcased two significant advancements in industrial metal additive manufacturing: the FS1521M-U and the Beam Shaping Technology. The FS1521M-U now supports up to 32 500W fiber lasers, combined with a 3,862L build volume, aimed at enabling faster, high-quality mass production, reducing material waste and improving economic manufacturing. Meanwhile, the new laser beam shaping technology optimizes laser spot profiles, enabling higher speeds, improved detail, and better part quality.Expanding Large-Scale Metal 3D Printing with the FS1521M SeriesIn 2023, Farsoon introduced the FS1521M series, which features 16 lasers and offers a standard build cylinder of 1530mm 1530mm 850mm (FS1521M) or a high-cylinder build volume of 1530mm 1530mm 1650mm (FS1521M-U). This series was designed for industrial-scale production of large-format metal parts. Since its release, the FS1521M series has been adopted by industrial customers globally, recognized for its design and performance.The updated FS1521M-U offers a build volume of 3,862 liters and supports up to 32 500W fiber lasers, enabling high-speed, high-precision printing while maintaining part quality. The upgraded FS1521M series also features 4 overflow and 4 recycling powder hoppers, supporting up to 4 powder recycling units. Each unit has a processing rate of 90L/h, with a combined maximum processing rate of 360L/h, ensuring more efficient and seamless production. Additionally, the platform offers versatile build volume configurations, either circular or square, to optimize powder usage and reduce costs.Farsoons FS1521M-U. Image via: FarsoonAdvancing Metal Additive Manufacturing with Beam Shaping TechnologyFarsoon is also introduced its Beam Shaping Technology, designed to improve precision, efficiency, versatility and overall performance in metal powder bed fusion systems. This innovation has been integrated into the FS350M-4, a mid-sized production platform featuring quad 1000W lasers and a 433 358 400mm build volume.Beam Shaping Technology enables dynamic laser spot configurations, such as ring-shaped or point-ring patterns, which can be tailored to specific applications. By optimizing laser power distribution and scanning strategies, this technology enhances print quality and efficiency for a range of materials, including stainless steel, aluminum alloys, and titanium alloys, achieving part densities exceeding 99.95%.In addition to improving print quality, Beam Shaping Technology increases printing speeds by widening melt pools by 50100% and boosting build rates by over 2.5 times.It is designed to minimize melt pool spatter, enhance thermal stability, and enable intricate details such as thin-wall structures. The technologys compatibility with high-thermal conductivity materials, including copper alloys, expands its applications across industries such as consumer goods, mold manufacturing, 3C electronics, aerospace, and precision casting.Beam Shaping Technology has been demonstrated across multiple Farsoon metal systems, including the FS721M-H-8-CAMS, FS350M-4, FS273M, and FS191M. Looking ahead, Farsoon plans to extend Beam Shaping Technology to larger platforms, including the FS621M, FS811M, and meter-scale systems, further advancing metal additive manufacturing capabilities.Farsoons Beam Shaping Technology. Image via: FarsoonFarsoons Previous Innovations in Metal Additive ManufacturingIn December, Farsoon introduced the Flight HT601P-4, a large-format polymer powder bed fusion (PBF) system featuring four 300-watt fiber lasers. The new system offers a substantial build volume of 600 600 600 mm (216 liters), enabling the efficient production of large components or high-volume batches.Fiber lasers in the Flight HT601P-4 achieve scanning speeds of up to 20 meters per second, significantly boosting productivity and operational efficiency. Its interchangeable build cartridge design supports continuous production workflows, minimizing downtime and maximizing throughput. Additionally, the compact footprint allows for optimized factory layouts, enhancing production yield within limited floor spaces.In November, Farsoon introduced the FS191M, a next-generation metal powder bed fusion (PBF) machine designed to enhance productivity and cost-efficiency across a range of industrial uses. Building upon the foundation of its FS121M system launched in 2016, the new system aims to offer a scalable solution for both pilot projects and low-volume manufacturing.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 showsFarsoons FS1521M-U. Image via: FarsoonPaloma DuranPaloma 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.

A group of Chinese researchers have developed a novel approach for addressing erectile dysfunction (ED) using biomedical 3D printing.In what is believed to be a world first, scientists successfully tested a 3D printed penile implant system in animals, reporting full restoration of erectile function in treated subjects. Published in Nature Biomedical Engineering, their findings offer promising insights into regenerative solutions for ED, a condition that affects more than 40% of men over 40, according to South China Morning Post.The study involved hydrogel-based bioinks to create an implant that closely mimics the anatomical and functional components of natural erectile tissue. Tested on pigs and rabbits, the technology yielded exceptional results while untreated subjects had a 25% reproductive success rate, those that received the implant showed a 100% success rate in mating and reproduction.Alongside South China University of Technology (SCUT), contributions also came from Guangzhou Medical University, Tokyo Medical and Dental University, and Columbia University.Lead author Wang Yingjun, an academician at the Chinese Academy of Engineering and President of the National Engineering Research Centre for Tissue Restoration and Reconstruction at SCUT, said, These findings indicate that the implants markedly improved functional recovery.The researchers used a hydrogel to 3D print a model of the corpus cavernosum a key structure in the penis that fills with blood during an erection. Next, they seeded this scaffold with endothelial cells the main cells that line blood vessels. Image via SCUT.A complex structure recreated with precisionNaturally, the penis has one of the most intricate vascular networks in the body, making reconstruction particularly challenging. Two corpus cavernosa run along its length, playing a key role in erections, while the tunica albuginea, a tough connective tissue layer, helps sustain them.To replicate these structures, researchers developed a hydrogel-based bioink, primarily composed of acrylic acid gelatin, to 3D print the corpora cavernosa. The implant was then encased in a fiber-based artificial tunica albuginea, providing the necessary strength to maintain function.For a more realistic and functional reconstruction, the team also 3D printed the corpus spongiosum, another erectile column, and the glans penis, assembling all components to mirror natural anatomy. To improve biocompatibility and reduce the risk of immune rejection, a layer of endothelial cells was added to the surface, supporting natural integration into the body.The study divided subjects into three groups: one received the 3D printed implant alone, another received both the implant and endothelial cells, while a control group with penile injuries received no treatment.The control group showed a 25% reproductive success rate, while those with 3D printed implants alone reached 75%. For the group that also received endothelial cells, the success rate climbed to 100%, indicating that the additional cell layer enhanced tissue regeneration and function.Recovery was swift. Two weeks after surgery, the animals regained normal erectile function, and within six weeks, they successfully mated and reproduced. The researchers noted that the findings suggest 3D printed hydrogel implants could restore damaged erectile tissue to near-normal function.Beyond ED treatment, the study highlights the potential of 3D printed functional tissue models for other organs with intricate circulatory networks, such as the heart and lungs. While previous research has explored these models, large-scale animal testing has been limited. The researchers emphasized that their study provides valuable insights into how 3D printed implants could translate into real-world applications, particularly in regenerative medicine.Although human trials are still a long way off, the study presents an important foundation for future research. If similar success is achieved in humans, this approach could lead to personalized, biologically compatible solutions for ED, offering an alternative to existing treatments.Local deformation to damage and flow measurement. Image via SCUT.3D printing for vascular organ reconstructionSCUTs approach aligns with broader efforts in bioprinting, where researchers are developing vascularized tissues, such as engineered blood vessels and functional heart models, to improve transplant success and advance regenerative medicine.For instance, Pohang University of Science and Technology (POSTECH), The Catholic University of Korea, and City University of Hong Kong (CityUHK) researchers successfully 3D printed biomimetic blood vessels and implanted them in a living rat, demonstrating a potential breakthrough in vascular grafts for cardiovascular disease treatment.Using a triple-coaxial cell printing technique and a specialized bioink made from smooth muscle and endothelial cells, the team developed functional vascular structures that integrated with living tissue over several weeks. The study suggested that these engineered blood vessels could offer a durable alternative for small-diameter vascular grafts, with future research focusing on enhancing their strength and evaluating long-term performance for human applications.In the US, researchers from the University of Minnesota developed a bio-ink that enabled them to 3D print a functional beating human heart, contributing a novel approach in cardiac tissue engineering.Leveraging pluripotent stem cells, they created an aortic replica with enhanced chamber structure and cell wall thickness, overcoming previous limitations in cardiac bioprinting. The printed heart maintained its electromechanical function for over six weeks, demonstrating potential applications in drug testing, disease modeling, and regenerative medicine.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the researchers used a hydrogel to 3D print a model of the corpus cavernosum a key structure in the penis that fills with blood during an erection. Next, they seeded this scaffold with endothelial cells the main cells that line blood vessels. Image via SCUT.

Researchers from Massachusetts Institute of Technology have developed a new way to grow artificial muscle tissue that contracts in multiple directions, mimicking the movement of natural muscles more closely than ever before.Published in Biomaterials Science, this technique introduces a microtopographical stamping method that precisely controls how muscle fibers form and align. With potential applications in biohybrid robotics, regenerative medicine, and muscle disease research, the findings could help bridge the gap between engineered and biological tissue.At the center of the research is Simple Templating of Actuators via Micro-topographical Patterning (STAMP), a fabrication process designed to shape muscle growth with microscopic precision.Instead of relying on traditional, complex fabrication methods, the team turned to a surprisingly simple approach, using a 3D printed stamp to create structured grooves in a soft hydrogel. These grooves guide muscle cells as they grow, ensuring they align into functional fibers that can contract in multiple orientations.The study was led by Ritu Raman, the Eugene Bell Career Development Professor of Tissue Engineering at MITs Department of Mechanical Engineering. Funding for the study was provided by the U.S. Office of Naval Research (ONR), the U.S. Army Research Office, the National Science Foundation (NSF), and the National Institutes of Health (NIH).MIT engineers grew an artificial, muscle-powered structure that pulls both concentrically and radially, much like how the iris in the human eye acts to dilate and constrict the pupil. Image via MIT.Artificial iris shows controlled muscle contractionsTo put the method to the test, the researchers created an artificial iris, a biohybrid actuator designed to replicate the way a human eyes pupil expands and contracts.The structure featured two distinct muscle fiber arrangements: one forming concentric circles, the other radiating outward. Both worked together to produce controlled contractions in response to light stimulation, demonstrating a level of coordination rarely seen in engineered muscle tissue.Natural muscle fibers dont grow in perfect straight lines. In the body, their orientations vary, allowing for a wide range of movement. Artificial muscle designs, however, have traditionally been limited to pulling in a single direction.That limitation made it difficult to develop biohybrid actuators capable of complex, multi-axis motion. With STAMP, muscle growth can now be directed in more intricate patterns, bringing artificial tissue a step closer to functioning like its biological counterpart.Accessibility was a key factor in developing the stamping process. Using high-resolution 3D printing, the team fabricated stamps with microscopic grooves that matched the dimensions of individual muscle cells.A protein coating on the stamp ensured clean imprinting onto the hydrogel without damaging the material. Once pressed into place, the stamp created a precise blueprint for muscle fibers to follow. The result was a structured tissue network that maintained its function over extended periods.In addition, computational modeling played a crucial role in validating the technique. Simulations predicted that muscle fibers grown with the STAMP method would contract in a coordinated, multi-directional manner, a prediction that was confirmed through experimental testing.The artificial iris performed as expected, demonstrating the ability to control pupil constriction in a way that closely resembled natural function. While the study focused on skeletal muscle, the method isnt limited to one cell type. Researchers believe it could be adapted for neurons, heart muscle cells, and other tissues to create precisely structured bioengineered materials.Looking ahead, the team sees applications beyond medicine. Muscle-based actuators could provide energy-efficient alternatives to rigid mechanical components in soft robotics, particularly in environments where flexibility is crucial. The ability to create multi-degree-of-freedom (multi-DOF) movement could make biohybrid robots more adaptable and dynamic.The researchers developed a new stamping approach. First, they 3D printed a small, handheld stamp (top images) patterned with microscopic grooves, each as small as a single cell. Then they pressed the stamp into a soft hydrogel and seeded the resulting grooves with real muscle cells. The cells grew along these grooves within the hydrogel, forming fibers (bottom image). Image via MIT.3D printing advances in artificial muscleAway from MIT, Researchers at Northwestern University developed a soft, flexible actuator that allowed robots to mimic human muscle movement through expansion and contraction. Led by Professor Samuel Truby, the device was tested in a worm-like soft robot and an artificial bicep, which successfully lifted 500 grams 5,000 times without failure.Made from rubber and thermoplastic polyurethane, the actuator was low-cost and adaptable, addressing safety and flexibility challenges in robotics. Published in Advanced Intelligent Systems, the study demonstrated potential applications in human-centric environments, offering a cheaper alternative to rigid actuators traditionally used in robotic systems.Three years ago, researchers at the Italian Institute of Technology (IIT) developed a robotic hand that used SLA 3D printed artificial muscles to grip objects with human-like efficiency. This hand was powered by GeometRy-based Actuators that Contract and Elongate (GRACEs), made from a pleated resin membrane that stretched and contracted like biological muscles.An 8-gram actuator lifted 8 kilograms, demonstrating its strength and flexibility. The team connected 18 actuators to enable human-like finger and wrist movements, proving that functional artificial muscles could be 3D printed in a single step, simplifying the fabrication of soft robotic systems.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows MIT engineers grew an artificial, muscle-powered structure that pulls both concentrically and radially, much like how the iris in the human eye acts to dilate and constrict the pupil. Image via MIT.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

With the 2025 Formula One season now underway, 3D Printing Industry takes an exclusive look insideOracle Red Bull Racingwith the team that propelled driver Max Verstappen to his fourth championship victory in the World Drivers Championship.Visiting the Red Bull headquarters and factory in Milton Keynes, we take a deep dive into Red Bull Racings strategy, car development, and the technological advances that contribute to its success.Formula One is among the most watched sports in the world; its also one of the most secretive. Teams make great efforts to protect their cutting-edge advantages, including painting fake bolts or rivets to disguise the true construction of the cars. During my factory tour, I spotted a black and white car shell evidencing such subterfuge and designed to throw rivals off the scent.With such levels of secrecy, I leaped at the opportunity, kindly provided by scanning specialistHexagon, to tour the Red Bull factory. During the visit, I saw where the crews practice pit stop changes, heard from the race strategist regarding tactics, and took a look behind the curtain at where some 90% of one of the most successful vehicles in the history of the sport are made.Red Bull Racing in Milton Keynes. Photo by Michael Petch.Determining a winning strategyAt the core of every Formula 1 strategy lies a hierarchy of key variables that determine race outcomes, with tire degradation as the fundamental factor. Guillaume Ducreux, Race Strategy Analyst at Oracle Red Bull Racing, said, If we had a tire that wouldnt degrade at all, all races would be zero-stop eventsthere wouldnt be any strategy.The next most influential element is overtaking difficulty. If you have a track like Monaco, even with high tire degradation, you can stay out and defend track position, Ducreux explained. This leads to a different strategic approach compared to circuits with wider overtaking zones.Safety car probability ranks third, with its impact varying significantly between tracks. In Monaco, the likelihood is very high, so you really have to think about it. But at a track like Suzuka, where safety car deployment is much lower, its less of a factor, he said. These variables form a complex matrix of probabilistic scenarios, requiring teams to make decisions based on likelihoods rather than certainties.Unpredictable factors, such as weather, complicate strategy further. We dont have, and I dont think any team has, a model that can predict rain timing with full accuracy, said the strategist.Building to Win and an Incoming Rule Change on the HorizonNo two Red Bull Racing cars are ever identical from one race to the next. Adjustments in setupride height, rake angle, camber, and other parametersare continuously refined based on circuit characteristics, tire conditions, and aerodynamic efficiency.At Red Bull Racings Milton Keynes headquarters, Oliver Glimmerveen, Technical Partnerships Lead, provided insights into the intricate process of race car development, where marginal gains translate directly into on-track performance.The process of preparing an F1 car for a race weekend is methodical and exhaustive. Every component manufactured across the facility is assembled in a space identical to the race garage. Before a race weekend, we fully assemble the car to 100% and then check that we have built it correctly, Glimmerveen explained. We use Hexagons metrology solutions, like laser scanners on tripods, to ensure parameters like ride height and camber angles are set with absolute precision.Once validated, the car is dismantled, transported to the circuit, and reassembled in the race garage. Any deviationwhether a millimeter shift in suspension height or a minor aerodynamic misalignmentcan impact handling. Ride height can be a one- or two-millimeter difference that completely changes the feel of the car for the driver, he added.Formula 1 operates on a strict regulatory framework, with teams working within design cycles dictated by governing bodies. The current regulations, introduced in 2022, are nearing their final stages before the 2026 rule change. As teams reach the limits of permitted development, finding performance gains becomes increasingly challenging. By the last year of a regulation cycle, cars are running at the absolute peak of what the rules allow, says Glimmerveen.Looking ahead to 2026, new regulations will alter the power dynamics of Formula 1, further complicating strategy. The cars will be smaller but potentially heavier due to larger battery packs, Ducreux explained. The electrical engine will be much more dominant, allowing drivers to deploy all available battery power to overtakebut with the trade-off of completely draining their energy reserves.This creates a fundamentally different decision-making process. Do you drain your battery to pass an opponent, knowing theyll have the opportunity to re-overtake soon after? Or do you conserve energy for a decisive move later in the race? said the partnerships lead. Energy management will become a critical component of race strategy, making it an even greater challenge for engineers and strategists alike.In preparation for the next major regulatory shift in 2026, Red Bull Racing has taken a bold step by developing its own powertrain division. The move was prompted by Hondas decision to scale back its involvement in Formula 1, leaving Red Bull with a strategic decision: seek an external supplier or bring engine development in-house. Do we go with a Renault engine? Probably not. Would Mercedes give us one? Lets be honest, no, said Kat Farmer, Senior Technical Partnerships Manager at Oracle Red Bull Racing.Instead, Red Bull Powertrains was established, with Ford joining as a technical partner to develop battery technology. The decision to build an entirely new engine from scratchwhile still competing for championshipsreflects Red Bulls confidence in its technical capabilities. When you consider we are still a subsidiary of an energy drinks company, designing and building the worlds most advanced F1 engine is a pretty impressive feat, Farmer noted.Oracle Red Bull Racing cockpit view. Photo by Michael Petch.What you cant measure, you cant manage.Mass manufacturing is accelerating, but specialist manufacturers are just as focused on quality and speed, says Stephen Chadwick, President EMEA of Hexagons Manufacturing Intelligence divisionCentral to this transformation is metrology, the science of measurement, where Hexagon is pioneering advanced quality inspection solutions. From laser scanning technologies to automated data analysis, the company is enabling manufacturers to integrate real-time quality control into production, reducing waste and improving efficiency.Hexagons quality inspection and metrology solutions play a crucial role in Red Bulls ability to maintain its competitive edge, ensuring precision in engineering while keeping up with the extreme pace of Formula 1 development cycles.Hexagons expertise extends far beyond motorsport. The company, a silent force behind many industrial transformations, operates across multiple sectors, from automotive to aerospace and energy. With over 27,000 active customers, 24,000 of whom are small to medium enterprises embedded within supply chains, Hexagon is deeply integrated into manufacturing ecosystems.Hexagons technology plays a critical role in measuring and verifying components before they hit the track. One notable example is its early access to the AbsoluteScanner AS1 scanning system, with Red Bull Racing gaining a six-month head start on the use of the technology.Mark Foden, Head of Quality Control at Red Bull Powertrains, reflected on the origins of this partnership: The partnership came to fruition about 18 years ago. Hexagon had the right piece of kit at the right time. The initial technologya basic AT901 trackerhas since developed into a suite of high-precision instruments, including handheld 3D scanners, laser trackers, and CT scanning systems.One of the most significant advancements has been the transition from single-point probing to full 3D scanning. Weve gone from a single point, which gave us very limited data, to now having handheld 3D scanners capable of taking hundreds of thousands of points per minute,Metrology in F1 is far from a one-size-fits-all process. Various tools are used depending on the scale and complexity of the components. Coordinate Measuring Machines (CMMs) remain fundamental for precision part inspection.Beyond the factory floor, laser trackers play an essential role in both vehicle setup and real-time race weekend operations. We carry two traveling trackersone static and one mobilewhich we use at circuits to validate car legality, Foden said. Pioneering the use of laser trackers in pitlane garages and influencing the FIAs adoption of similar practices across the paddock.We proved how we could set up ride height, toe, and camber in the race bay, then demonstrated the live-link process to the FIA, Foden explained. Thats probably our fault that you now see trackers in front of every car in the pitlane. We showed how the software and hardware could be used for regulation enforcement, and the FIA ran with it.Formula 1 cars are subjected to extreme forces during a race, leading to inevitable material expansion and flexing. Things will grow, things will distort, things will change, Foden explained. The FIA allows for damage and track-related deviations, but theyre very strict when it comes to structural elements. If an area is shifting beyond acceptable limits, we reassess the design to improve stability.From Physical Testing to Digital SimulationThe era of unlimited track testing in F1 is long gone. Decades ago, teams would conduct extensive test sessions between races, with separate crews running cars at circuits worldwide. Today, cost caps and regulatory constraints force teams to rely heavily on digital simulation. We used to have test teams running separate from race teams, but now, we only get one or two test weekends a yearBahrain and Barcelona, Glimmerveen explained. Everything else is done in the simulator or through computational fluid dynamics.This shift has made digital twin technology indispensable. The ability to run thousands of virtual iterations within cost cap constraints is a critical advantage. Formula 1s cost cap has introduced new logistical complexities, requiring teams to optimize every aspect of race operations. We cant just keep shipping things back and forth, Kat Farmer, Senior Technical Partnerships Manager, explained. We have five sets of our garage infrastructure so that we can use sea freightfar more cost-effective than air freight.Tailoring the Car to Each CircuitThe characteristics of different circuits also influence lap times, explains Farmer. Each Grand Prix presents unique aerodynamic and mechanical challenges, requiring tailored setups. Farmer outlined key differences between circuits, illustrating how Red Bull optimizes performance through car adjustments.MonacoA high-downforce, low-speed circuit that requires enhanced steering load adjustments. Its the only track where we allow drivers to fully cross their arms on the steering wheel to navigate the Fairmont Hairpin, she noted. Despite a strong pace in the early sectors, Red Bull struggled with low-speed mechanical grip compared to Ferrari and McLaren, which ultimately dictated qualifying results.MonzaKnown as the Temple of Speed, Monza demands low-downforce configurations to maximize straight-line performance. We use the skinniest rear wing possible, often referred to as the tea tray because its so thin, she said. The trade-off is reduced cornering stability, but the gains in top speed outweigh the drawbacks.Mexico CityThe highest-altitude race on the calendar presents unique air density challenges. At over 2,200m above sea level, even walking up stairs makes you breathe heaviernow imagine what that does to a Formula 1 engine, Farmer explained. To compensate, Red Bull adds extra cooling outlets while balancing aerodynamic efficiency, ensuring the engine does not overheat while maintaining optimal downforce levels.Engineering at Red Bull Racing: Precision, Performance, and Technological IntegrationKat Farmer also provided a detailed breakdown of the teams design and development process, highlighting the technological sophistication that underpins the RB20s performance. From CAD modeling to wind tunnel testing, every element of the car is meticulously engineered to extract maximum performance within Formula 1s stringent regulations.From Concept to Track: The Engineering WorkflowThe process begins in Computer-Aided Design (CAD), where a team of engineers model every component of the car, considering everything from aerodynamic efficiency to thermal management. Its not just pen and paper like the old days, Farmer explained. We design every single detailelectrical components, chassis beams, and heat dissipationbefore anything physical is built.The CAD models are then analyzed using Computational Fluid Dynamics (CFD), a virtual wind tunnel that simulates airflow over the car. We run these simulations to predict how the car will behave aerodynamically, she said. If we see inefficiencies, we can go back to CAD and refine the designwithout ever producing a physical part.Once optimized, the design progresses to simulator testing, where drivers provide real-time feedback on handling and car behavior. Our simulator is far beyond a PlayStation setup, Farmer noted. It replicates every curb in Imola, every chicane in Monaco, and every high-speed section in Austin, giving us invaluable data before we even reach the wind tunnel.The FIA Formula One World Constructors Championship Trophy. Photo by Michael Petch.Wind Tunnel Testing and 3D-Printed ComponentsRed Bull Racings current wind tunnel is located in Bedfordshire, a seventy-year-plus facility used for testing and development of supersonic flight and later for Concorde components. However, with advancements in Formula 1s cost cap regulations and efficiency demands, the team is constructing a new in-house wind tunnel in Milton Keynes, scheduled to be operational in 2026.We are only allowed to test at 60% scale in the wind tunnel, so we rely heavily on 3D printing, Farmer explained. Its not cheap, but its significantly faster and more cost-effective than traditional manufacturing. These scaled components are tested under simulated airflow conditions, with data fed back into CFD models to validate real-world aerodynamic performance.Once all tests confirm the designs viability, full-scale production begins, and the parts are integrated into the RB20 chassis. To validate the final design, Red Bull Racing employs flow visualization testing, a process where fluorescent flow paint is applied to the car during test runs. It looks like someones thrown bright yellow or pink paint over the car, Farmer said. But the patterns it creates allow us to analyze real airflow displacement and compare it with our CFD predictions.We scan components throughout manufacturing and use that data to provide real-time feedback to design, identifying where we are struggling and where improvements can be made, Foden said. For example, the aero department can analyze deviations between scanned components and predicted performance models, using that information to refine future designs.This process is particularly critical in aerodynamically sensitive areas such as front wings, underbodies, and diffusers, where even minute deviations can have a measurable impact on performance. We can correlate our scanned data with pressure taps and CFD simulations to understand whether manufacturing variations are affecting real-world performance, Foden noted.Composite materials, particularly carbon fiber, present some of the greatest measurement challenges. Anything carbon or composite is difficult to manufacture to tight tolerances. Floors are particularly sensitive, and theyre also one of the biggest areas for aerodynamic performance. The challenge of scanning reflective surfaces, such as carbon fiber components with resin layers, had previously limited the effectiveness of non-contact measurement methods. Now, we have no issues scanning glossy surfaces, which is crucial when dealing with aerodynamic components, says Foden.A staggering number of trophies at Red Bull Racing. Photo by Michael Petch.3D Printing at Red Bull RacingNew manufacturing technologies, particularly additive manufacturing, have introduced additional complexities. Designers can now create any shape they want, and they do. The challenge is measuring it, said Foden.While 3D printing has long been a crucial tool for wind tunnel model development, its role in Formula 1 has expanded to include structural and performance-critical components. At Red Bull Powertrains, additive manufacturing is now used across the car, with applications ranging from titanium direct metal laser sintering (DMLS) parts to functional brackets and saddles.We do have various components dotted around the car where we are using titanium DMLS productssome that require post-machining, some that dont, said Mark Foden, Head of Quality Control at Red Bull Powertrains. There are some very critical parts on the car that are DMLS, including structural elements.The ability to produce complex geometries quickly has made additive manufacturing a valuable asset, but it also presents new metrology challenges. With 3D printing, they can design anything they wantand they do, Foden noted.The transition from race to roadFormula One has always been a laboratory for transition from race to road, said Ignazio Dentici, VP Automotive of Hexagons Manufacturing Intelligence division. Think about electronics, active suspensions, automated manual transmissionsthese innovations first appeared in Formula One before being adopted in passenger cars.Agility is another key factor. The rapid development cycles in motorsport are now mirrored in mainstream manufacturing, where automakers are pressured to cut development times and costs. Advanced manufacturing methods, such as additive manufacturing and generative design, are shortening production timelines.Inspection time has also been slashed by up to 75%, as companies integrate automated quality control processes. Hexagons solutions facilitate seamless transitions between design, manufacturing, and inspection, streamlining workflows and improving efficiency.As production shifts towards electric vehicles, manufacturers must scale up battery production while maintaining cost efficiency. Dentici pointed to digitalization, automation, and supply chain localization as critical areas of investment.Reducing costs is an obsession today, he said. The same principles of cost reduction and performance optimization seen in Formula One are now being applied across the entire industry.In design, we provide tools for structural, material, and acoustic simulation, Dentici said. For production, our software solutions enable automated manufacturing, especially for high-precision machining and sheet metal fabrication.Metrology, historically a final checkpoint in manufacturing, is now embedded throughout the entire product lifecycle. Hexagons solutions range from physical and optical metrology to non-destructive testing, allowing manufacturers to detect internal defects that may compromise long-term reliability.Metrology isnt just about inspecting a finished partits about creating a closed-loop system where real-world measurements refine digital models, he said. By integrating test data into digital twins, we can make simulations more accurate and reduce physical prototyping.Adding AI to the mixAs manufacturers collect increasing amounts of production data, managing and interpreting it effectively is becoming a key challenge.The more data you gather, the more computational power and processing capability you need, Dentici explained. Automation and AI allow manufacturers to filter useful insights from the overwhelming amount of raw data, ensuring that the right information is applied to improve production efficiency.Hexagon is seeing significant momentum in AI-driven inspection technologies, particularly in battery production. One such application, using a computed tomography spectral layer, allows manufacturers to examine the internal structure of a battery beyond conventional electrical tests.You can test a battery, and it may pass, but defects inside could lead to thermal events after thousands of hours of use, Dentici explained. With AI, we can identify invisible risks and prevent failures before they occur.The future of manufacturing is self-learning, Dentici said. Machines will autonomously decide how to inspect parts based on real-time production data.Hexagon is expanding its suite of AI-driven manufacturing solutions to address the specific challenges of electric vehicle (EV) production. The shift from internal combustion engines (ICE) to battery powertrains is forcing a rethink of design and production processes, requiring new technical developments and data-driven approaches.Producing a battery-powered EV is not the same as producing a four-cylinder engine or an eight-speed automatic transmission, said Ignazio Dentici, VP Automotive at Hexagons Manufacturing Intelligence division. With ICE powertrains, manufacturers know exactly what to optimizethe eigenvalues, the frequencies, the key performance metrics. With EVs, the challenge is different. What needs to be prioritized for safety and efficiency in production? This is where new AI-powered tools become critical.Hexagon is developing bespoke use cases for battery systems and powertrains, integrating machine learning to improve predictive modeling, defect detection, and process optimization. The complexity of battery manufacturing, with its strict thermal and structural integrity requirements, demands real-time monitoring and adaptive quality control systems.While data models and advanced technology provide a framework for decision-making, drivers real-time feedback remains crucial. Sometimes the driver completely disagrees with the model, Race Strategy Analyst Ducreux admitted. The simulation might suggest pitting in 10 laps, but if the driver is yelling on the radio that the tires are gone, we have to compromise.The balance between predictive data and human judgment defines a strong strategy team. There are times when we cant see what the driver is feeling in the data, so we trust the model. But when their feedback is confirmed by telemetry, we adjust accordingly, said Ducreux.Perhaps this is an important reminder that when technology meets the high demands of a sport like Formula 1, people still remain a critical factor for success.For more in-depth and exclusive articles, subscribe to the3D Printing Industry newsletter. You can also follow us onLinkedIn, and subscribe to the3D Printing Industry Youtubechannel.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?Featured image shows many Red Bull Racing Formula One cars. Photo by Michael Petch.Michael PetchMichael Petch is the editor-in-chief at 3DPI and the author of several books on 3D printing. He is a regular keynote speaker at technology conferences where he has delivered presentations such as 3D printing with graphene and ceramics and the use of technology to enhance food security. Michael is most interested in the science behind emerging technology and the accompanying economic and social implications.

West Japan Railway Company (JR West) is turning to 3D printing technology to construct a train station building in 6 hours, marking a first in the railway infrastructure.Partnering with JR West Innovations Co Ltd and Serendix Inc, the company has confirmed plans for a new station at Hatsushima Station on the JR Kisei Main Line in Wakayama Prefecture. Some railway stations in Japan, especially in rural areas, still have wooden structures, including the one at Hatsushima. With many aging stations in need of renewal, the project aims to enhance efficiency while evaluating the feasibility of this construction method for future applications.A computer rendering shows a minimalist white shed under a curved roof. Image via JR West.Compact station with cultural designThe station building will be a single-storey structure made of reinforced concrete, covering just under 10 square meters. It will stand 2.6 meters high, stretch 6.3 meters wide, and reach a depth of 2.1 meters. In a nod to local culture, the walls will feature images of Arida Citys famous oranges and tachiuo fish.The designing is being handled by Nouveau First Class Architect Office Inc, First Class Architect Ota Koji, and JR West Osaka First Class Architect Office, with structural work carried out by KAP First Class Architect Office and Osaka First Class Architect Office.Key building components, including the foundation, will be produced using an undisclosed 3D printer and reinforced with concrete before being transported to the site. Once delivered, a crane will be used for assembly, with the entire process from start to completion expected between the last evening train and the first in the morning.This approach will allow the structure to be built between the last train at night and the first train the next morning, preventing disruptions to railway operations. Compared to traditional steel frame and reinforced concrete methods, the use of 3D printing is expected to reduce construction time while streamlining on-site work, according to JR West.Durability is a key factor in the project. Reinforced concrete provides resistance to environmental wear, and eliminating the need for formwork allows for more flexibility in shaping the structure. With this method, station buildings can be designed to better fit their surroundings, creating facilities that are both practical and visually suited to their locations.This initial construction will serve as a test case to assess cost-effectiveness in both the building process and long-term maintenance. If successful, JR West and its partners will look into expanding the concept to other station locations.The method is also being explored as a potential solution to labor shortages in railway construction by reducing dependence on conventional, labor-intensive building techniques.3D printings growing role in railway infrastructureJapans latest development is the latest in a long list of instances where 3D printing was used in railway infrastructure.Back in 2021, contractors responsible for the London terminal of the UKs High Speed 2 (HS2) rail network announced plans to introduce 3D printing into its construction starting in 2022. Using Printfrastructure, a process developed by construction 3D printing company ChangeMaker 3D, they aimed to print concrete slabs on-site to streamline tunnel construction while minimizing disruption to existing rail lines.Led by SCS JV, a joint venture of Skanska, Costain, and STRABAG, the project also incorporated graphene-infused concrete to reduce reliance on steel, potentially cutting material use and carbon emissions by up to 50%. The approach was expected to improve efficiency and sustainability.Adopting ChangeMaker 3Ds technology could help put HS2 back on track. Image via HS2. Last year, Italian 3D printer manufacturer WASP launched a project to repurpose abandoned tunnels beneath Milans central railway station, enhancing them into a creative hub for architecture and design. Inspired by the 1960s Drop City in Colorado, the project introduced Dropcity as a space for creative collaboration.During Milan Design Week, work started on Tunnel 54 using WASPs Crane WASP and experimental Crane WASP Scara printers to 3D print office spaces and furniture directly on-site. A Clay 3D Printing Farm contributed by producing intricate architectural elements. From April 12 to 21, visitors were invited to explore the site and witness the construction process firsthand.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows a computer rendering shows a minimalist white shed under a curved roof. Image via JR West.

Californian space launch company Rocket Lab has entered into a non-binding term sheet with select lenders to acquire a controlling equity stake in Mynaric AG, a German manufacturer specializing in laser communication technology.The agreement, pending approval, would allow Rocket Lab to strengthen its position as a leading launch provider, spacecraft manufacturer, and satellite component supplier. Additionally, the transaction would establish Rocket Labs first European base in Munich, Germany, integrating a skilled team of over 300 engineers and unlocking new market opportunities across the region.This acquisition aligns perfectly with our long-term vision. Mynarics laser communication technology will play a key role in advancing our capabilities, helping us scale solutions for both commercial and government customers, said Rocket Lab Founder and CEO Sir Peter Beck.Rocket Labs satellite. Image via: Rocket LabStrategic Acquisition for Satellite and Space OperationsRocket Labs interest in acquiring Mynaric stems from their established partnership, with Mynaric supplying optical communication terminals for Rocket Labs $515 million contract with the Space Development Agency (SDA). Additionally, Mynarics involvement in other SDA contracts and its shared customer base across the commercial, defense, and government sectors aligns with Rocket Labs strategic expansion objectives.Rocket Lab also sees an opportunity to address the growing challenges faced by constellation operators in securing high-volume, cost-effective laser communication solutions. Leveraging its expertise in transforming satellite subsystems and components from limited availability and long lead times into scalable, affordable solutions, Rocket Lab plans to apply this approach to Mynarics optical terminals.If completed, the acquisition would provide Rocket Lab with control over Mynarics production facilities, intellectual property, inventory, and backlog related to satellite-to-satellite optical communication solutions. This would further enhance Rocket Labs satellite technology portfolio and support its broader strategy of vertically integrating manufacturing and operations for advanced satellite applications.We have been very clear about this strategic direction for several years now Rocket Lab is pursuing every part of the space value chain. We launch our own rockets, build satellites in constellation volumes, and now were closing in on the final step and most valuable part of the space economy operating our own constellations to provide data and services from space using our newly announced Flatellite spacecraft. Mynaric has paved the way in developing laser technology. Their team and technologies will make a compelling addition to our satellite component portfolio, and we look forward to making the technology available at scale for our own constellations and those of our customers, said Beck.Rocket Labs Electron rocket. Photo via: Rocket LabAcquisition TermsThe non-binding term sheet with the Lenders outlines Rocket Labs proposed acquisition of Mynaric, contingent on completing the StaRUG Restructuring and canceling all outstanding equity interests as per Mynarics restructuring plan. The term sheet also includes an exclusive negotiating period between Rocket Lab and the Lenders, subject to due diligence and the negotiation of a definitive agreement, which will require regulatory approvals. Rocket Lab emphasized that the acquisition is not guaranteed.If finalized, Rocket Lab would acquire 100% of Mynarics equity for $75 million, payable in cash or Rocket Lab stock, at Rocket Labs discretion. An additional earn-out of up to $75 million, based on Mynarics future revenue, may also be paid in cash or stock. If the Lenders or their affiliates invest more capital in Mynaric after the restructuring but before the acquisition, the purchase price will increase, and the earn-out amount will be reduced accordingly.Rocket Labs Space and Aerospace EffortsSince its inception, Rocket Lab has established a strong reputation for delivering reliable commercial launches, successfully deploying over 100 satellites. In 2022, the company launched NASAs CAPSTONE satellite toward lunar orbit using its Electron rocket. This mission represented a significant advancement in the Artemis program, as CAPSTONE became the first spacecraft to follow the planned Near Rectilinear Halo Orbit (NRHO) trajectory for NASAs Gateway lunar outpost.In a recent development, Rocket Lab has partnered with Kratos Defense & Security Solutions in a $1.45 billion, Pentagon-backed hypersonic missile testing program. The MACH-TB 2.0 initiative, which is one of the largest investments in U.S. hypersonic infrastructure, aims to accelerate the development of hypersonic technologies by expanding flight test capacity and mitigating risks associated with transitioning new capabilities into operational use.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 showsRocket Labs satellite. Image via: Rocket LabPaloma DuranPaloma 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 NOVA University of Lisbon have developed a new approach to evaluating additive manufacturing (AM) maturity, offering a more precise way for companies to assess their progress.Having applied fuzzy logic, the researchers created a model that captures the nuances of AM adoption, addressing the gaps in traditional maturity models that often fail to account for real-world complexities.While AM has become a key part of Industry 4.0, seamlessly integrating it into manufacturing workflows is far from straightforward. Many organizations find themselves in a transitional phase, where AM is being used to some extent but hasnt yet become a core part of production.Traditional maturity models often categorize companies too rigidly, making it difficult to identify specific areas for improvement. To address this limitation, the fuzzy AM maturity model (Fuzzy AMMM) offers a more flexible assessment that accounts for human judgment and the uncertainties inherent in technological adoption. Fuzzy AMMM development method. Image via NOVA University of Lisbon.Evaluating AM maturity across strategy, workforce, and technologyPublished in Procedia Computer Science journal, the model evaluates AM maturity across three key areas: organizational, cultural, and technological. Organizational maturity looks at whether AM is integrated into a companys strategy, how committed leadership is, and the level of investment in AM projects.Cultural maturity assesses workforce readiness, employee skills, and openness to AM adoption, while technological maturity focuses on how well AM is implemented in production processes, including CAD software use and part manufacturing.To put the model to the test, the researchers conducted a case study at an undisclosed automotive supplier that has been using AM for five to ten years.The assessment involved a combination of surveys and interviews with company representatives, including an operations manager with expertise in mechanical engineering. Results indicated an overall AM maturity level of 3, placing the company at an intermediate stage where AM is in use but has yet to significantly impact production.A closer look at the scores revealed a strong performance in organizational and technological maturity, both ranking at 4.68, suggesting that the company has integrated AM into its strategy and production workflow. However, cultural maturity lagged at 3.00, pointing to a gap in workforce training.Employees showed proficiency in CAD software, design for additive manufacturing (DFAM), and slicing software, but there was a noticeable lack of personnel with leadership skills to oversee AM operations. Additionally, while some external training initiatives exist, there is no structured internal competency development program, limiting long-term growth.One of the studys key findings was a disconnect between leaderships commitment to AM and employee readiness. The company had made substantial financial investments and adapted its processes, but without dedicated AM specialists and structured training programs, it faced challenges in maximizing AMs potential.This underscores a broader issue seen across industries, having the right technology in place is only part of the equation. Without the necessary skills and expertise among employees, full integration remains out of reach.By applying fuzzy logic, the researchers were able to capture a more accurate and realistic picture of AM maturity compared to conventional models, which tend to oversimplify the assessment process. According to the researchers, the Fuzzy AMMM not only helps organizations determine where they stand but also highlights the specific areas that need improvement.Future research aims to expand the models application across multiple industries, refining its framework to support organizations as they navigate their AM journey. With clearer insights, businesses can make more informed decisions, ensuring that AM integration becomes not just a technical upgrade, but a strategic advantage.Novel approaches to assessing AM maturityAdding to this years expert predictions, Paul Gradl, Principal Engineer at NASA Marshall Space Flight Center, stated that developing an AM maturity model could help standardize processes and refine material properties, contributing to the future of 3D printing.At Formnext 2023, industry players including Siemens, DyeMansion, Forward AM, EOS, and HP introduced the Additive Manufacturing Industrialization Navigator (AM I Navigator) initiative. Designed to address industrial 3D printing challenges, the initiative outlines a structured maturity model to help companies integrate AM into traditional workflows.Through this tool, companies can evaluate their AM maturity through a Maturity Check, based on Siemens Digital Manufacturing Excellence framework, to identify gaps and receive recommendations for improvement. The goal is to support a transition from manual to fully autonomous AM production while optimizing process coordination.Left to right: Franois Minec (Global Head, Polymers 3D Printing, HP 3D Printing), Martin Back (Managing Director, BASF Forward AM), Karsten Heuser (Vice President Additive Manufacturing, Siemens Digital Industries), Felix Ewald (CEO & Co-Founder, DyeMansion) & Nikolai Zaepernick (CBO, Managing Director, EOS). Photo via DyeMansion.While structured maturity models provide a roadmap for AM adoption, some companies take a more direct approach by focusing on quality assurance. Parts sourcing AM platform MakerVerse and ZEISS showcased a range of dimensional, surface, and material property assessment solutions, enabling companies to systematically evaluate the reliability of their AM parts.Through Optical 3D Scanning, Tactile CMM, Surface Roughness measurements, and Industrial CT/X-ray inspections, this platform offers a data-driven approach to AM maturity, ensuring that printed parts meet certification standards and are suitable for full-scale production.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the Fuzzy AMMM development method. Image via NOVA University of Lisbon.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

At IDS 2025, Carbon, a U.S.-based developer of CLIP 3D printing, will showcase its latest advancements in automation, material technology, and workflow optimization, all designed to enhance the efficiency of dental labs. The company will introduce new features in its Automatic Operation (AO) Suite and unveil Lucentra, a solution for clear aligner production. These innovations aim to improve productivity and support scalable production in the dental industry.Weve seen these solutions contribute to significant improvements across North America, and were eager to extend that success to Europe at IDS 2025. Our goal is to help dental labs unlock new levels of productivity and efficiency, said Terri Capriolo, Senior Vice President of Oral Health at Carbon.Dental model made from DPR 10 resin. Photo via CarbonHighlights of the AO SuiteAt the core of Carbons presentation will be the AO Suite, which includes the AO Backpack, the Automatic Print Preparation (APP), all-new Parts Retrieval Basket, and AO Polishing Cassettes for M-Series printers.Launched in 2024, the AO Backpack introduces significant automation to post-print operations, featuring an automatic separation blade for efficient removal of parts from the build plate, a parts basket capable of collecting up to 230 parts, and a resin reclamation system that supports cost-effective and sustainable production. Since its introduction, the AO Backpack has processed over 18,000 prints, improving workflows in dental labs.To optimize workflow, the Automatic Print Preparation (APP) enhances laboratory efficiency by automating essential pre-print tasks such as part orientation, support placement, and labeling. The APP can operate independently or in conjunction with the AO Backpack, streamlining the print preparation process, maintaining a steady print queue, and reducing the need for manual intervention.The Parts Retrieval Basket allows labs to retrieve completed prints without disrupting ongoing operations. This functionality is particularly advantageous for labs using the AO Backpack during staffed shifts, ensuring continuous production and minimizing downtime.The AO Polishing Cassette has been introduced to the European lab market and is now compatible with M3 and M3 Max printers. It utilizes light-scattering technology to polish parts during the printing process, resulting in smoother, clearer prints while reducing manual finishing and preserving intricate design details. The cassette has been validated for materials such as Dentsplys Lucitone Digital Print and Keystone Keysplint Soft Clear, and is available for the M2, M3, and M3 Max printer platforms.Lucentra: Enhancing Clear Aligners ProductionIn line with its commitment to automation, Carbon is introducing Lucentra, a solution designed to reduce visible layer lines in thermoformed clear aligners by producing smoother printed models, thereby enhancing clarity from the outset. Lucentra integrates specialized software, a new cassette for the Carbon L1 printer, and UMA 20, a material formulated for creating hollow models and offering a longer shelf life compared to previous aligner model materials.Lucentra solution. Photo via: CarbonAdvancements in Digital DentistryIn related news, Stratasys has introduced TrueDent-D resin to the European market, enabling the production of over 30 dentures in a single print job using the J5 DentaJet printer. This resin significantly reduces production costs by more than 50% compared to traditional methods, addressing the growing demand in a market projected to reach $2.45 billion by 2028. The streamlined process also eliminates more than 27 manual touchpoints, reducing errors and chair time for patients.Meanwhile, 3D Systems, based in the U.S., received FDA 510(k) clearance for its multi-material, jetted 3D-printed denture solution. This new technology integrates NextDent Jet Denture Teeth and NextDent Jet Denture Base materials into a single monolithic denture using MultiJet Printing. The solution emphasizes break resistance, aesthetics, and high-volume production, improving automation and efficiency in denture manufacturing.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 Lucentra solution. Photo via: Carbon

Chinese 3D printer manufacturer PioCreat has teamed up with the U.S.-based 3D printing startup Helio Additive to integrate Dragon, a physics-based 3D print simulation and optimization software, into its printer ecosystem. As part of this collaboration, every Piocreat G5 Ultra and G12 printer will come with a Dragon license, enhancing the performance and capabilities of their 3D printing solutions.With Dragons integration, Piocreat customers will benefit from hands-off printing, reducing failures and minimizing manual adjustments through physics-driven automation. The software enhances layer bonding, reduces warping and defects, and ensures more reliable parts across a broader material range, all while speeding up print times without compromising quality.We designed Dragon to maximize the potential of every 3D printer, and this partnership with Piocreat makes it effortless for customers to experience its benefits, said David Hartmann, CEO of Helio Additive. Together, we are making high-performance 3D printing more accessible and scalable.Starting May 1, Dragon will be available as a trial version with all new Piocreat 3D printers. Customers can activate a full subscription through Piocreats reseller network or directly via Helio Additive.Laboratory experiments. Photo via Helio Additive.Dragon: Automation, Precision, and Cost-Efficiency In 2024, Helio Additive launched its Dragon software platform, designed for process simulation and optimization to improve productivity and reduce costs in large-format additive manufacturing (LFAM). This software addresses a widespread challenge in the industry: users often set process parameters without sufficient data, leading to unpredictable outcomes and increased costs from waste, under-utilized materials, and extended engineering time.In an interview with 3D Printing Industry, David Hartmann emphasized Dragons significant impact on large-scale, granular-based additive manufacturing. He explained that the software allows users to digitally experiment with parameter sets, drastically reducing waste and improving efficiency. One notable case study highlighted the savings of over 300 kilos of material and four weeks of engineering labor, resulting in a 70% reduction in scrap for a single part.The Dragon software. Image via Helio Additive.A Wave of Software InnovationsThe additive manufacturing (AM) industry has seen a surge in software advancements. In 2024, Ai Build introduced AiBuild 2.0, a cloud-based platform certified with ISO 27001 for data security. Making its debut at RAPID + TCT 2024 in Los Angeles from June 25-27, this update integrates enhanced automation features and marks a collaboration with WASP to integrate its CAREBRO robotic-arm 3D printing tool. Aibuild 2.0 seeks to optimize industrial additive manufacturing processes, enhance accessibility through AI assistance, and support a range of technologies, including polymer extrusion and metal Direct Energy Deposition (DED).Elsewhere, 3D printing materials producer HYBRID Softwares subsidiary AMIS launched the beta version of AMIS Pro software, aimed at binder jetting additive manufacturing.AMIS Pro is positioned as a CAD in, print out build preparation tool that supports both Mac and Windows, offering post-CAD and pre-print functionalities. During its beta phase, AMIS Pro is available for free, allowing users to batch-prepare parts for 3D printing. It includes a 60-day trial period and provides an opportunity for users to share feedback.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 showsLaboratory experiments. Photo via Helio Additive.Paloma DuranPaloma 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.

Chinese 3D printing technology firm SUNLU 3D recently launched the FilaDryer E2, its latest 3D printing filament dryer.When 3D printing with hygroscopic, engineering materials, moisture-induced part defects can be a frustrating experience that wastes filament, time, and money. SUNLUs newest FilaDryer seeks to change this.The desktop-sized system can simultaneously dry two filament spools at temperatures up to 110C, making it compatible with almost all engineering-grade materials on the market. Reportedly the first filament dryer of its kind to exceed 80C, it also offers annealing capabilities, something rarely seen in the consumer space. This advanced feature allows users to unlock improved strength, durability, and impact resistance for their final parts.3D Printing Industrys engineering team has put the FilaDryer E2 through its paces in an exclusive first look at the new system. This article explores its key features, benefits, user experience, and performance across a range of advanced materials and applications.Prices start at $349.99, positioning the FilaDryer E2 at the higher end of the filament drying market. However, advanced features help set it apart from the competition. With a compact design and user-friendly interface, the system is ideal for newcomers and hobbyists. Advanced annealing capabilities also make the E2 a strong choice for professionals targeting high-performance applications.The SUNLU FilaDryer E2 filament dryer. Photos by 3D Printing Industry.Why choose the SUNLU FilaDryer E2?The SUNLU FilaDryer E2 is a two-in-one system that offers filament drying and part annealing in the same box. On the drying side, the unit supports engineering-grade and standard materials, offering compatibility with 1.75 mm and 2.85 mm filaments.With 500W PTC heating power, the E2 can reach 50 in just 20 minutes and boasts maximum temperatures up to an impressive 110. This unlocks the ability to dry most 3D printing filaments on the market, including challenging hygroscopic materials like TPU, Nylon, and PETG.Thanks to its sizeable 372 x 192 x 255 mm internal dimensions, SUNLUs new offering can store two 1kg or 2kg regular spools for simultaneous, time-efficient drying. A single 3kg spool can also fit at any one time. While the dryer is broadly compatible with most filament brands, users should verify spool dimensions for optimal fit.Annealing is an essential post-processing step for professional users targeting functional parts where mechanical properties are key. During this process, a 3D printed part is heated to a specified temperature, and then slowly cooled. This helps to relieve the internal stresses that build up in 3D printed parts, helping to minimize warpage, brittleness, and shrinkage. The result? Parts that possess superior strength, durability, and heat resistance, essential requirements for functional prototypes and end-use components.Thanks to its high internal temperature, the E2 can reportedly anneal parts 3D printed with 99.99% of engineering materials on the market. These include ABS, ABS-CF, ASA, PC, flame retardant PC, PC-ABS, PC-PBT, CoPA, and PA variants like PA6-GF, PA6-CF, and PA12.Annealing a part inside the SUNLU FilaDryer E2. Photo by 3D Printing Industry.Advanced filament drying and annealing made easyThe SUNLU FilaDryer E2 is optimized for ease of use, offering advanced material drying and annealing with a low barrier to entry.Its 95 55 mm monochrome backlit touchscreen is an intuitive and user-friendly interface for adjusting system parameters. The touchscreen is responsive and enables smooth navigation, allowing users to easily modify settings.The E2 includes built-in drying settings for many common filaments to streamline and accelerate operations. More advanced users can manually set temperature and drying duration to meet specific material requirements. The interface also provides live monitoring of key drying conditions, a feature we found especially useful for ensuring optimal filament performance.Featuring a sleek, minimalist design, SUNLUs FilaDryer E2 features a high-quality build optimized for its high-temperature capabilities. Its cover plate utilizes silicone strips and a magnetic suction block to ensure secure airtightness and insulation, keeping water vapor outside the sealed chamber.Equipped with a dual-level temperature control system, the system automatically disconnects power if the dryer overheats, restoring operation once the temperature stabilizes. Thanks to its double-layer insulation, the E2s surface temperature remains below 60C even when the internal environment exceeds 100C.The SUNLU FilaDryer E2s touchscreen user interface. Photo by 3D Printing Industry.Testing filament drying applicationsMost polymer materials are hygroscopic, meaning they absorb moisture from the air. Even small amounts of moisture in 3D printing filaments can negatively affect print success. Does the SUNLU FilaDryer E2 improve part quality? To find out, we conducted several tests comparing parts 3D printed with and without the filament dryer.One common issue that typically impacts moist filaments is stringing. During 3D printing, moisture heats up and evaporates inside the nozzle, increasing internal pressure. This can force filament to extrude during 3D print head movements, stringing unwanted material between part features.Our retraction test with SUNLU Easy PA clearly shows that using the FilaDryer E2 can significantly reduce stringing and improve surface quality.SUNLU Easy PA retraction test. Photos by 3D Printing Industry. A bracket mount was also 3D printed using moist SUNLU Easy PA. This part exhibited several issues, including excessive stringing and rough surface finish caused by moisture-induced steam expansion during extrusion.After drying the filament, however, the print quality significantly improved. Layer bonding became much stronger, eliminating delamination. The surface also became noticeably smoother, with minimal stringing. The dried material produced a structurally sound part with improved mechanical strength, making it far more suitable for functional applications.SUNLU Easy PA bracket mount test. Photos by 3D Printing Industry. PA12-CF is another engineering-grade material susceptible to moisture. After 3D printing an automotive bonnet air scoop with undried material, we noted weaker layer adhesion and suboptimal surface finish. Support removal was also difficult, as moist parts broke off into smaller segments rather than as a whole part.After drying the filament with the SUNLU FilaDryer S4, the 3D print quality improved significantly. Layer bonding was much stronger, minimizing delamination, and the surface finish became smoother with reduced defects. Dimensional accuracy was also much better, as the filament extruded more consistently without moisture-related instability. Additionally, the dried filament exhibited enhanced mechanical strength and improved thermal resistance, making it better suited to high-performance applications.PA12-CF automotive bonnet air scoop test. Photos by 3D Printing Industry. In a second retraction test, we found that undried PA12-CF filament caused the spikes to lack definition and layer consistency. This led to a poor surface finish and dull points on the model. After drying, the material achieved much higher definition spikes and impressive layer consistency, again proving the value of SUNLUs new Filadryer.PA12-CF retraction test. Photos by 3D Printing Industry.Another material infamous for its hygroscopicity is TPU. This was confirmed when we 3D printed an induction air duct using the undried filament. High moisture absorption caused inconsistent extrusion and frequent nozzle clogging. As the moisture evaporated, steam expanded within the nozzle, disrupting material flow and causing a catastrophic print failure.After drying the TPU 95A material, we observed immediate improvements in printability. The extrusion rate became significantly more consistent, ensuring a smooth, uninterrupted material flow. This greatly reduced stringing, improved layer adhesion, and facilitated a much cleaner surface finish. The dried TPU also exhibited superior elasticity and mechanical strength, as the absence of moisture prevented layer inconsistencies and brittleness.TPU 95A air duct test. Photos by 3D Printing Industry.Ultimately, the SUNLU FilaDryer E2 is a great option in the FDM 3D printing market. It combines beginner-friendly operation with advanced, professional-grade functionality for advanced prototyping and production applications. It stands out from the competition thanks to the unique combination of drying and annealing in a single unit, helping to justify the high-end price point.Our testing confirmed that the filament dryer effectively removes moisture from engineering-grade hygroscopic materials. Filament dried with the E2 produced noticeably superior results, minimizing surface defects, improving dimensional accuracy, and enhancing overall functionality. More importantly, it provides users with peace of mindreducing the risk of failed prints and ensuring filament is always in optimal condition for reliable, high-quality production.The intuitive user interface and in-built material presets streamline material drying and annealing for more efficient 3D printing. Therefore, SUNLUs new FilaDryer is an essential tool for functional applications requiring flexibility and strength.Technical Specification of the SUNLU FilaDryer E2NameFilament Dryer E2Package Dimensions454mm 276mm 362mm(LWH)Net/Gross weight6.1KG / 7KGOuter Dimensions400mm 220mm 307mm(LWH)Operating EnvironmentTemperature: 10-35RelativeHumidity: 95%Working Temperature Range35-110*ColorBlackMaximum Operating Current2.2A @230V 4.2A@120VCompatible Filament Diameters1.75mm/2.85mm/3.0mm*The first one in the industry to exceed 80C.Who won the 2024 3D Printing Industry Awards?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows the SUNLU FilaDryer E2. Photo by 3D Printing Industry.

GE Aerospace, a global leader in aircraft propulsion and engine manufacturing, will invest nearly $1 billion in its U.S. factories and supply chain in 2025. The initiative, nearly double last years commitment, is intended to increase manufacturing capacity, enhance engine safety and quality, and support the development of advanced aerospace materials. The investment will impact more than two dozen communities across 16 states.A significant portion of the investment$500 millionwill go toward expanding production and assembly capabilities for the narrowbody CFM LEAP engine, produced through a joint venture between GE Aerospace and Safran Aircraft Engines. Deliveries of these engines are expected to rise by 15-20% in 2025. Facility upgrades and additional equipment will be installed at several locations, including a $113 million investment in Greater Cincinnati to enhance commercial and military engine production, a $70 million expansion in Muskegon, Michigan, to manufacture hot-section engine components, and $16 million and $5 million for facilities in Durham, North Carolina, and Lafayette, Indiana, respectively, to support commercial engine assembly.In addition, $200 million will be allocated to military engine production. GE Aerospace is preparing for large-scale manufacturing of the T901 engine for Black Hawk and Apache helicopters, with investments directed at sites in Lynn, Massachusetts, and Madisonville, Kentucky. The company continues to produce propulsion systems for U.S. military aircraft, with engines powering two out of three U.S. military combat and helicopter aircraft.An artists interpretation of a hypersonic vehicle. Image via GE Aerospace.More than $100 million will be directed toward scaling production of next-generation aerospace materials, including ceramic matrix composites (CMCs) and additive manufacturing technologies such as 3D printing. These materials improve fuel efficiency and durability, allowing for higher operating temperatures and reduced engine weight.Facilities in Auburn, Alabama, and West Chester, Ohio, will receive $51 million and $14 million, respectively, for expanded 3D printing capacity, industrial furnace installations, and additional manufacturing equipment. In Huntsville, Alabama, a $22 million investment will fund new machines for CMC material production, while Asheville, North Carolina, will receive $20 million for additional equipment to produce CMC engine components and high-precision metal shaping machines. Batesville, Mississippi, will see an $11 million investment in inspection technology, industrial ovens, and precision machining tools.Hiring efforts are also increasing, with GE Aerospace planning to add around 5,000 new employees in 2025. This follows the companys hiring of more than 900 engineers and 1,000 manufacturing workers in 2024. In addition to direct hiring, GE Aerospace and its foundation have contributed $2.3 million toward workforce development programs across multiple communities.With an installed base of approximately 45,000 commercial and 25,000 military aircraft engines, GE Aerospace plays a significant role in global aviation. Engines developed by the company and its joint ventures power three out of four commercial flights worldwide.GE Aerospace Logo. Image via GE Aerospace.Aerospace Investment in Additive ManufacturingSintavia, an additive manufacturing service provider specializing in aerospace components, received a $10 million investment from the Stifel North Atlantic AM-Forward Fund, a program aimed at expanding additive technology in U.S. aerospace and defense manufacturing. This follows Sintavias $25 million expansion plan announced in April 2024, which funded new large-format 3D printers, post-processing equipment, and component testing capabilities. As part of the expansion, the company secured a contract with the U.S. Department of Defense to develop 3D printed hypersonic propulsion components.In Ohio, a newly established Aerospace and Defense Innovation Hub in Youngstown received $26 million from the states Innovation Hubs Program, with an additional $36 million from local, federal, and private sources. The initiative is focused on research and workforce development in additive manufacturing for defense and aerospace applications. Youngstown has been a center for additive manufacturing, with America Makes playing a key role in promoting 3D printing advancements in the region. The facility is expected to generate 450 jobs by 2029 and increase state revenue by $161.6 million.Sintavias Team. Photo via: SintaviaReady 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 GE Aerospace Logo. Image via GE Aerospace.Anyer Tenorio LaraAnyer 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.

AMAZEMET, a Warsaw-based company specializing in metal additive manufacturing and ultrasonic atomization, has developed a high-energy laser-melting source to improve the efficiency and purity of its ultrasonic atomization process. The system was developed as part of the INNOPOWDER project, a European Union-backed initiative focused on advancing metal powder production technologies.Unlike conventional melting systems, which rely on consumable electrodes and generate risks of tungsten contamination, the laser-based source offers a highly concentrated heat application. This allows for more efficient atomization of high-performance materials while minimizing undesired element evaporation. The new system will be incorporated into the rePowder atomization platform, AMAZEMETs metal powder production system designed for high-purity material processing.Laser-melted and ultrasonically atomize C103 powder. Image via AMAZEMET.ukasz rodowski, CEO and inventor at AMAZEMET, highlighted the benefits of integrating laser energy into ultrasonic atomization. Laser-beam unlocks new capabilities in ultrasonic atomization. The integration of a precise and highly concentrated heat source allows us to expand the range of materials that can be effectively atomized. By eliminating contamination risks associated with traditional plasma sources, we achieve cleaner, more controlled atomization with improved powder quality. The ability to fine-tune the energy input of a 6kW laser through advanced scanning strategies enables a new level of process control for high-performance materials, like C103. We are confident that laser-based ultrasonic atomization will redefine industry standards in powder manufacturing.The laser system enables the atomization of a broad range of materials, from lightweight aluminum to high-melting-point metals such as titanium and niobium. Eliminating the need for consumable electrodes removes the risk of tungsten contamination, addressing a major challenge in high-purity powder manufacturing. The lasers precise energy input also allows for optimized scanning strategies, integrating methodologies used in Laser Powder Bed Fusion (L-PBF) and Electron Beam Powder Bed Fusion (EB-PBF) to improve process efficiency.Laser-based ultrasonic atomization process. Photo via AMAZEMET.Integration of the system is part of a broader effort by AMAZEMET to refine sustainable metal powder production. The company holds multiple patents for its ultrasonic atomization technology and continues to develop its intellectual property portfolio. Additional technical details on the laser system will be released in 2025 as part of ongoing research and development.Developments in Laser-Based Powder ProcessingThe application of laser technology in metal powder processing has been advancing across multiple areas of additive manufacturing. nLight, a company specializing in semiconductor and fiber lasers, introduced the AFX-2000 beam-shaping laser for laser powder bed fusion (L-PBF). The AFX-2000 uses dynamic beam shaping to distribute energy more evenly, improving print stability by up to 40%. During testing, an undisclosed aerospace and automotive industry customer used the AFX-2000 to 3D print aluminum components three times faster than standard large-format 3D printers. The systems beam-shaping capabilities allow switching between different profiles optimized for contour exposure and high build rates, increasing process efficiency.Research into metal powder bed fusion has also explored defect mitigation strategies. A study from Carnegie Mellon University and the University of Pittsburgh examined shrinkage porosity in Inconel Alloy 718 during L-PBF. The researchers developed a heat transfer model to explain how solidification cooling rates affect porosity formation, identifying key processing parametersincluding laser power, scanning velocity, and deposition temperaturethat influence defect severity. Shrinkage porosity process maps were introduced as a tool for manufacturers to adjust printing conditions to minimize defects in high-temperature metal additive manufacturing.Illustration of shrinkage porosity formation in solidifying metal. Image via Acta Materialia.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 Laser-based ultrasonic atomization process. Photo via AMAZEMET.Anyer Tenorio LaraAnyer 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.

AMPOWER has published its latest report, an exceptionally comprehensive collection of proprietary first-hand data and analysis on the additive manufacturing industry.3D Printing Industry readers can access an exclusive 10% discount on the 2025 AMPOWER Report using the code 3DPI2025.Data on the additive manufacturing sector is often fragmented, with some companies reluctant to share split figures across geographies, technologies, and industrial verticals. The problem with data is that there are different sources, said AMPOWER Managing Partner, Matthias Schmidt-Lehr. Forecasting from startups compounds the issue. In early years, emerging companies frequently set ambitious targets.AMPOWERs report draws on a network of large, established users of additive technologies for more realistic projections. Aerospace, defense, energy, and medical sectors are highlighted as core markets, each featuring clear roadmaps for how they deploy additive production.The resulting report, published today, shows the industry has a current market size of EUR10.72 billion, growing at 13% CAGR by 2029. For comparison, the 2023 figures were a market size of EUR10.50 billion, with 13.9% CAGR until 2028. By machine sales, the leading AM technology is metal Powder Bed Fusion at 39% (2023: 40%).Headline figures from the AMPOWER Report:Market slowdown in 2024 2% growth as customers postponed equipment investmentsStrong material consumption +17% growth in tons, signaling increased utilizationIndustry consolidation Fewer new startups, a shift toward profitability, and strategic refocusingSector-driven demand Aerospace & Defense, Energy, and Medical remain key growth areasAMPOWER findings suggest that equipment revenues may flatten, but materials show more promising growth, bolstered by higher machine utilization among end users. The part-manufacturing service bureau market is said to be under strain, particularly those offering one-off and prototype parts. Contract manufacturers with smaller client bases and steady production orders fare better, while broader prototyping services face tougher conditions and competition from low-cost suppliers. Meanwhile, Chinese service providers are gaining traction among overseas customers with simpler application requirements.AMPOWER Global Metal and Polymer Additive Manufacturing Market Size. Image via AMPOWER.When will AM growth resume?Some industry observers anticipated slowing growth for additive manufacturing, but a more pronounced flattening from 2023 to 2024 has emerged. I did not expect a flat line or even a decline in total market volume, said Schmidt-Lehr. He suggested that enthusiasm seen over the past year had not translated into sustained growth, with some companies deferring capital investments amid uncertain market conditions.Several factors appear to be driving this pause. One is the need to absorb prior machine acquisitions. Many users had previously expanded their machine fleets in anticipation of increasing production needs, but that capacity now exceeds immediate demand. Schmidt-Lehr noted that companies purchased machines without actually utilizing them and that todays priority is increasing utilization and productivity rather than additional equipment spending.Despite slower equipment sales, material usage is reportedly on the rise. Schmidt-Lehr says this points to healthy machine utilization levels, particularly in sectors with a clear roadmap for production, such as energy, aerospace, and defense. While overall additive manufacturing remains on a long-term growth trajectory, near-term challenges persist for businesses experiencing declines in sales and confronting management changes.Analysts attribute part of the uneven landscape to macroeconomic factors, including interest-rate shifts and widespread political transitions, which have weighed on capital expenditure decisions. Regional variances also figure prominently, with additive machinery sales in North America holding firmer than in Europe. The general sentiment among industrial users remains positive, but many are pausing new equipment investment until current assets are fully deployed.AMPOWER Global Metal and Polymer Additive Manufacturing equipment revenue. Image via AMPOWER.Several market forecasts have suggested that equipment sales for additive manufacturing may rebound strongly in the second half of 2025. AMPOWERs Managing Partner takes a cautious view: Yes, our data still shows there will be continuous growth, which reflects the customer feedback and supply chain feedback. But this is based on interviews in January and the beginning of February. Recent geopolitical shifts may bring additional uncertainties to the equation.Market uncertainties extend beyond traditional economic cycles. Trade tariffs and protectionist policies have limited influence on sectors such as metal AM, Schmidt-Lehr says, because leading players in the United States typically produce locally. However, potential project delays across industries could slow machine purchases. Machinery manufacturers are also wary. Given fluctuating demand and ever-shifting policies, several have become reluctant to issue forward-looking statements.AMPOWERs data points to an evolving competitive landscape. Growth is no longer fueled by nascent entrants expanding the overall market. We are definitely out of this startup phase, Schmidt-Lehr says. Its all about fighting for the piece of cake you want to achieve. This heightened competition is likely to spur a wave of acquisitions and mergers, reshaping a sector that has historically featured a steady flow of new businesses.Schmidt-Lehr adds that the new AMPOWER study is an important milestone, providing the strategic groundwork for companies seeking to identify and defend their market share. As flat or declining figures become a reality, established firms may look to consolidate positions or explore inorganic growth, rather than rely on an industry-wide surge in demand.The strategic approach to value creation with 3D printingIndustry insiders are questioning the wisdom of selling 3D printing as a broad offering, instead favoring application-focused models. It becomes more difficult to sell 3D printing, said Schmidt-Lehr. You either win with cost, or you win with quality and focus. A wave of machine manufacturers have pivoted to specialized sectors, demonstrating a move away from one-size-fits-all solutions. He cites how Formlabs has established itself through simple, budget-friendly systems such as the Formlabs Fuse, while high-end equipment suppliers now concentrate on aerospace, energy, and healthcare.Schmidt-Lehr confirms that additive manufacturing has made strides toward the maturity levels seen in CNC processes. He cites energy-sector clients achieving 95% machine availability and 75-80% utilization ratesfigures that would have been unthinkable only a few years ago. Alongside this operational progress, growing material consumption underlines a commitment to making full use of existing installed capacity.Although current economic trends have dampened expectations, projections still favor expansion in the mid-term. We do still project growth, and the reason for that is mostly the application users who keep mentioning that what theyre currently doing in AM keeps unlocking new applications, Schmidt-Lehr added. Aerospace, defense, energy, medical, and industrial tooling could see the greatest gains, given that most companies in these areas say they are far from exhausting additives potential.This measured optimism contrasts with an older vision for AM of universal devices suitable for any manufacturing task, or what might be called replicator syndrome. In the way CNC technology evolved to serve distinct niches, additive methods appear to be charting a parallel courseoperators either compete on cost and simplicity or pursue specialized markets that promise higher margins and product differentiation.Updates on AM progress in key vertical marketsOne reason for the decreased equipment revenue last year, said Schmidt-Lehr, was not only the flat line in number of equipment but also the decreased pricing. On the metals side, the market is diversifying at both ends: sub-100k machines targeting dental and other niche segments and large-scale equipment for aerospace applications dominated by Chinese providers.Aerospace and defense remain robust in metals, but full-scale commercial aircraft programs are hampered by protracted development timelines. Defense work, often linked to spare and sustainment parts, still leans heavily on R&D. Steady, if incremental, demand also stems from medical and dental, which Schmidt-Lehr describes as very reliable, pointing to consistent implant and dental applications that helped offset weaker performance elsewhere. Heat exchangers are another bright spot in metals, with software advancements, such as generative design for lattice structures, expanding design possibilities, and boosting system-level performance. Notably, enterprises, including nTop, are unlocking these applications.Polymers have seen consumer-driven growth, including applications in sports equipment and protective gear, helped by affordable desktop selective laser sintering devices. As Schmidt-Lehr put it, these polymer machines can match prior industrial specifications at a fraction of the cost, prompting users to substitute larger or legacy systems with smaller, targeted solutions that excel at prototyping and mid-volume runs.A Deeper Dive into the 3D Printing Start-up SegmentAdditive startups appear to be operating in a more cautious funding environment, according to the new AMPOWER analysis. We had the highest peak in 2022 with about four to 4.2 billion Euros invested in startups, said AMPOWER Managing Partner, Matthias Schmidt-Lehr. Now, in 2024, we see about 1 billion euros in documented investment rounds. He attributes the drop to investors increasingly favoring ventures that address specific industrial challenges rather than those that market 3D printing as a catch-all solution.AMPOWER Global Metal and Polymer Additive Manufacturing startup funding. Image via AMPOWERSchmidt-Lehr sees incremental innovation dominating among established players, with beam shaping (nLight, EOS/AMCM) and thick-layer printing in metals, or dual SLA/DLP (Axtra) systems in polymers, being prime examples. We have small, incremental innovations everywhere, he noted. Companies are buying their sixth, or seventh machine, and they dont want to be met with any more surprises. They want a reliable system, not necessarily brand-new technical features.Hardware developers targeting niche applications, such as printing tungsten carbides for fusion reactors or producing fuel-cell components, appear to have the best funding prospects. Some startups even avoid the 3D printing label to emphasize end-market integration. Schmidt-Lehr believes this underscores the importance of demonstrating clear economic returns for users rather than simply showcasing an innovative additive process.Learning from HistoryAsked how the sector might look if rebooted from day one, he responded: I dont know if it would look so much different. Its not a technology designed for one specific application. He points out that 3D printing stretches across a wide spectrum of materials, industries, and usesfrom high-end aerospace parts to routine prototypes.This range has required developers and service providers to court many verticals at once. Some have thrived on niche solutions, while others chased universal approaches. Schmidt-Lehr believes the industrys early focus on pursuing every possible market was inevitable. Youre forced to market a new technology across all kinds of verticals before you identify the use cases that are scalable and make money, he said.He added that if the industry could use current knowledge from the start, it might well concentrate on proven lucrative segments. Yet he doubts the overall playbook would shift dramatically. The breadth of additives applications remains both its defining strength and its biggest hurdle, shaping a path that is inherently more complex than traditional manufacturing technologies.Get the full 2025 AMPOWER Report at a discounted price with the code 3DPI2025.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 image shows the AMPOWER Report 2025. Image via AMPOWER.

Welcome to the latest edition of our 3D printing jobs and career moves update for the additive manufacturing sector.In this edition, well highlight recent developments and movements in the industrys workforce, shedding light on the dynamic landscape of the additive manufacturing sector.Read on for recent hires and facility openings at Ai Build, Materialise, Norco, Nikon Corporation, WAAM3D and more.New Hires at Norco, SWISSto12, Velo3D, WAAM3D, and moreKicking off with new hires, large composites, and GRP moldings manufacturer Norco has welcomed Max Osmond as the new head of Additive Manufacturing and CNC Development, reinforcing efforts to expand in advanced manufacturing. With a 27-year tenure as Director of MSA Manufacturing Limited, Osmond brings deep expertise in CNC kitting, 3D printing, and composite machining.Based in Ferndown, Dorset, MSA Manufacturing played a vital role in supplying composite materials before ceasing operations in 2024. At Norco, Osmond will focus on strengthening large-format 3D printing, streamlining CNC and additive workflows, and scaling operations. Industry relationships and technical knowledge position him to drive efficiency and innovation, with a long-term vision centered on team development and refining manufacturing processes for sustained growth.Max Osmond. Photo via Norco.Next up, Ben Morgan has stepped into the role of interim CEO at the Advanced Manufacturing Research Centre (AMRC), following the departure of Steve Foxley in December 2024.Previously serving as AMRCs research director and chief technology officer (CTO), Morgan will now lead the AMRC Board, collaborating with industrial partners, government bodies, and the wider team across South Yorkshire, Wales, and Lancashire. Since joining AMRC as a project engineer in 2009, Morgan progressed through key leadership roles, including head of the integrated manufacturing group at Factory 2050, where he led a team of over 70, and later as research director for more than five years.Ben said, I am excited and humbled to lead a wonderful organisation for which I have devoted my career. I look forward to working with the AMRC team, the wider University and colleagues across the High Value Manufacturing Catapult to continue to deliver impact to industry across the UK.Cranfield University spin-out WAAM3D has appointed Lee Chee Weng as its interim CEO at WAAM3D, following Filomeno Martinas decision to step down after six years of leadership. As a long-time board member, Lee also serves as Managing Director of Addept3D and Vice President of Advanced Manufacturing at Accuron.Martinas journey with WAAM3D began in 2010 as a Cranfield University MSc student, driven by a belief in the potential of wire arc additive manufacturing. Over the years, he helped grow the company from an academic team into a commercial enterprise, navigating challenges and expanding operations to Milton Keynes. While stepping away from day-to-day leadership, he remains a shareholder and looks forward to WAAM3Ds continued success under Lees guidance. Filomeno Martina, WAAM3D CEO, with the new MiniWAAM 3D printer at TCT3Sixty 2024. Photo by 3D Printing Industry.Swiss technology group Oerlikon has nominated Dr. Stefan Brupbacher, Marco Musetti, and Dr. Eveline Steinberger for election to its Board of Directors at the upcoming Annual General Meeting (AGM) on April 1, 2025. If approved, they will replace Irina Matveeva, Gerhard Pegam, and Zhenguo Yao, who are stepping down.With a strong background in economic policy and industry leadership, Brupbacher brings experience as Director of Swissmem and a board member at Orgalim. His previous role as Secretary General of the Swiss Federal Department of Economic Affairs, Education, and Research (EAER) involved shaping policies that supported Switzerlands industrial and technological growth. Plans are in place for him to take on the role of Lead Independent Director and chair the Governance Committee.Moreover, Musetti has spent years working across industries, holding board positions at medmix AG, Octo Telematics, GEM Capital, and United Kalahari Minerals. His expertise in corporate governance, business development, and investment strategy makes him a strong candidate for the Audit & Finance Committee. Additionally, his international experience adds a global perspective to the boards decision-making.As a specialist in AI, big data, augmented reality, and robotics, Steinberger founded The Blue Minds Company in 2014, focusing on digitalization and energy transition. Leadership roles at Siemens, the Climate and Energy Fund of the Austrian Federal Government, and VERBUND AG highlight her background in energy and infrastructure. As a Supervisory Board member at UniCredit Bank Austria, she brings additional financial and strategic expertise, with plans for her to serve on the Governance and Human Resources Committees.Apart from these changes, Oerlikons board structure remains unchanged, ensuring continuity while integrating fresh perspectives into its leadership team.Radio Frequency (RF) component supplier SWISSto12 has named Steve Collar as Chairman of its Board of Directors, bringing more than 30 years of experience in the satellite industry. His leadership at satellite communication service firm SES included five years as CEO, where he oversaw one of the worlds largest satellite operators.Before that, he spent over six years at O3b Networks, guiding the company from its early funding stages to a successful satellite constellation launch and commercial expansion. Under his direction, O3b became the fastest-growing satellite operator in the industry. Stepping into the role previously held by Roland Loos, who will remain on the board, Collar is set to contribute his expertise in scaling satellite businesses and driving industry growth.America Makes has appointed Andrew Thompson as chair of the Roadmap Advisory Group (RMAG) and Rick Russell as chairperson of the Executive Committee, bringing experienced leadership to guide the institutes strategic initiatives.Serving as Deputy Chief Engineer for Additive Manufacturing at Northrop Grumman Space Systems, Thompson will take charge of shaping RMAGs direction. His role involves leading key initiatives, recruiting members, engaging working groups, and ensuring the roadmap stays aligned with America Makes mission. He will also collaborate with the institute to maintain data, set priorities, and keep the Executive Committee informed on project call topics.As a chairperson, Russell will oversee the Executive Committee, working alongside industry experts from academia, government, and economic development sectors. His leadership will focus on implementing strategies, policies, and advocacy efforts that accelerate additive manufacturing adoption and enhance U.S. manufacturing competitiveness on a global scale.Supporting Russells efforts, Sandra DeVincent Wolf, Ph.D., has been appointed Secretary of the Executive Committee. As Executive Director of Carnegie Mellon Universitys (CMU) Manufacturing Futures Institute, she plays a key role in advancing manufacturing research. She also leads the NextManufacturing Center, a major hub for additive manufacturing research, where she manages partnerships, industry consortiums, and metals AM laboratories.Software development company ModuleWorks has appointed Amod Onkar as the Global Head of Marketing. He previously served as the Country Manager of India for SolidCAM. With over 25 years of experience in CAD/CAM and CNC machining, he brings expertise in strategic business development, team leadership, and industry innovation.During his tenure at SolidCAM, Amod expanded the companys customer base from two to over 1,200, driving a 20% annual growth rate in the past five years. He led a team of 72 engineers and sales professionals while advancing 3- and 5-axis milling technologies. His experience integrating ModuleWorks toolpath engines into SolidCAM products provides valuable insight for overseeing ModuleWorks global marketing and expansion efforts.I have known Amod for the past 20 years and could appreciate his work the whole time, especially his deep knowledge of CAM, says Yavuz Murtezaoglu, Managing Director and founder of ModuleWorks.Amod Onkar at ModuleWorks India. Photo via ModuleWorks.The Photopolymer Additive Manufacturing Alliance (PAMA) has appointed Vince Anewenter, Director of the Rapid Prototyping Consortium at the Milwaukee School of Engineering (MSOE), as the new Chair of its Executive Advisory Board. He takes over from David Walker, CTO of PrintFoam and Co-Founder of Azul 3D, who will continue with PAMA as Executive Advisory Board Chair, Ex-Officio.PAMA has also announced that Dr. Callie Higgins, a leading researcher at the National Institute of Standards and Technology (NIST), will step into the role in January 2027. She currently serves as the AM Coordinator for NISTs Material Measurement Laboratory and co-leads the Photopolymer Additive Manufacturing Project.Functioning as a collaboration initiative between NIST and RadTech, PAMA is dedicated to establishing industry-wide standards for photopolymer additive manufacturing. In 2025, the organization plans to focus on standardizing industry terminology and addressing the growing use of photopolymers in consumer and maker markets, particularly in terms of safety, health, and environmental considerations.Metal 3D printer manufacturer Velo3D has appointed Darren Beckett as its new CTO, entrusting him with guiding the companys technological direction and innovation efforts.In his new position at Velo3D, Beckett will oversee the development and execution of technology initiatives, ensuring they support the companys growth and align with industry needs. Having spent nearly 20 years at Intel Corporation, Beckett brings over 25 years of experience in technology leadership.His career also includes leadership roles at Woodruff Scientific, where he served as VP of Engineering, and Sigma Additive Solutions, where he worked as CTO. At Sigma, he played a key role in advancing additive manufacturing quality control technologies.New facility openings by AML3D, Materialise, Renishaw, Nikon, and moreMoving on to facility openings, Australian metal 3D printer manufacturer AML3D has launched its fully operational US technology center in Stow, Ohio, serving as its headquarters and a manufacturing hub.The facility currently houses an ARCEMY AM system for large-scale metal 3D printing, with a second system set for installation in early 2025. Stow is fulfilling a AUD$2.27 million order from the Tennessee Valley Authority (TVA), while AML3D plans to invest AUD$12 million to expand capacity in response to rising U.S. Department of Defense (DoD) demand, particularly for the US Navys Submarine Industrial Base.Led by Pete Goumas, President of US Operations, Stow also supports AML3Ds sales, administration, and technical teams. The expansion strengthens AML3Ds US Scale up strategy, which has secured over AUD$16 million in contracts since 2023, and enhances its ability to access ITAR-restricted defense contracts while positioning the company for potential US policy shifts favoring domestic manufacturing.Oil & gas company Aker Solutions has launched a 3D printing center in Trondheim to explore the potential of additive manufacturing (AM) for offshore maintenance and modifications. Developed together with Equinor, the ADDMO center is part of a seven-month pilot contract supporting operations at the Troll and Heidrun fields.At the center, engineers will work on integrating AM into daily workflows, focusing on reducing costs, improving efficiency, and lowering emissions by enabling on-demand production of spare parts. This initiative builds on experience from the Johan Castberg project, where 7,000 components were successfully 3D printed. With more than 50 AM systems now in use across multiple locations, Aker Solutions continues to expand the role of 3D printing in offshore asset management.Aker Solutions CEO Kjetel Digre (left) and EVP Life Cycle Paal Eikeseth at the opening of Aker Solutions 3D printing center ADDMO in Trondheim. Photo via Aker Solutions.London-based 3D printing software developer Aibuild has opened a new office in Silicon Valley to support its AI-powered AM operations in the U.S. Located within NIKONs research campus in the San Francisco Bay Area, the office will facilitate alliance between the two companies, with NIKON being one of Aibuilds key investors.This new site will serve as a research and development hub, allowing Aibuild to expand its customer base and form new partnerships with U.S. manufacturers. The company aims to contribute to supply chain sovereignty in industries such as aerospace, defense, and energy, which are considered critical to national security.Daghan Cam and Michail Desyllas, the founders of Aibuild said, Expanding into United States with a new office in Silicon Valley is a pivotal moment for Aibuild. Getting closer to our key customers and partners in the region will allow us to respond to their needs faster. Working alongside NIKON in our new location will also deepen our partnership and accelerate our efforts to bring AI-driven automation into manufacturing.Additionally, Nikon Corporation is set to open the Nikon AM Technology Center Japan in Gyoda, Saitama Prefecture, with a grand opening event planned for February 28, 2025. Following the launch of its AM Technology Center in Long Beach, California, in July 2024, the new facility will serve as a hub for advanced manufacturing in Japan and Asia.Equipped with Nikon SLM Solutions NXG XII 600 laser powder bed fusion (PBF) system, the first of its kind in Japan, the center will focus on metal additive manufacturing for defense, space, and aviation sectors. High-precision directed energy deposition (DED) systems, including the Lasermeister LM300A, will also be available for repair and sustainment applications across various industries.Global engineering firm Renishaw and IDEKO have opened a new Renishaw Solutions Centre in Elgoibar, Spain, to support research in advanced manufacturing. Located within the Basque Research and Technology Alliance (BRTA), the facility is part of a partnership agreement signed during the 2024 International Machine Tool Exhibition in Bilbao.Industry leaders, including Deputy Minister for Technology, Innovation, and Digital Transformation Jaione Ganzarain, attended the inauguration, where technologies for 3D measurement, process control, metal AM, and industrial robotics calibration were presented. Additionally, the partnership extends to machine tools manufacturer Danobatgroup alongside the engineering firm supplying advanced technologies to enhance manufacturing capabilities across multiple product lines.Renishaw and IDEKO team cutting the ribbon. Photo via Renishaw.Elsewhere, Belgian 3D printing software and services provider Materialise has opened an Aerospace Competence Center in the Aerospace Innovation Hub in Delft, becoming the first additive manufacturing (AM) company to establish a presence there. The company has produced over 500,000 3D printed aerospace parts annually, supporting OEMs, airlines, MROs, and supplier tiers.Establishing a base in Delft allows Materialise to work with TU Delft, startups, and industry professionals, contributing to research in sustainable aviation and advanced manufacturing. With EASA POA and EN 9100 certifications, the company is positioned to support new AM applications while improving supply chain efficiency, lead times, and part design flexibility. Industrial giants Airbus and Collins Aerospace are already part of the innovation hub, fostering broader partnerships in aerospace technology.The opening of our new Aerospace Competence Center aligns with our commitment to support the aerospace industry through more than three decades of experience in additive manufacturing and software solutions, as well as our pioneering role in producing certified parts, said Brigitte de Vet-Veithen, CEO of Materialise.What3D printing trendsshould you watch out for in 2025?How is thefuture of 3D printingshaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows 3D Printing Industry Jobs Board. Image via 3D Printing Industry.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

Researchers from South China University of Technology and Beijing Tsinghua Changgung Hospital analyzed the effects of heat treatment on laser powder bed fusion (LPBF)-fabricated CoCrMo alloys, focusing on microstructural changes, mechanical anisotropy, and residual stress reduction. The study examined how solution treatment at 1150C for one hour followed by annealing at 450C for 0.5 hours altered grain morphology, tensile strength, and elongation properties.CoCrMo alloys are widely used in orthopedic implants due to their corrosion resistance, wear resistance, and mechanical durability. When fabricated using LPBF, the layer-by-layer solidification process produces columnar grain structures aligned along the build direction, resulting in significant differences in mechanical properties depending on orientation. The research quantified these variations and assessed how heat treatment modifies the materials structure to address mechanical disparities.Microstructural Analysis of LPBF-Fabricated CoCrMo Alloys. Image via Materials Futures.Mechanical testing showed that as-printed CoCrMo samples exhibited 19.1% elongation along the build direction and only 9.3% perpendicular to it, a difference exceeding 100%. Ultimate tensile strength (UTS) was also higher along the build axis, measuring 1173.7 MPa compared to 1048.6 MPa in the perpendicular direction.Columnar grains, typically aligned in the <001> direction, restricted dislocation movement across grain boundaries, resulting in lower ductility perpendicular to the build axis. High dislocation densities at melt pool boundaries further influenced stress distribution, contributing to premature failure in the weaker orientation.Recrystallization Reconfigures Grain MorphologySolution heat treatment at 1150C for one hour induced full recrystallization, transforming columnar grains into equiaxed grains. Electron backscatter diffraction (EBSD) analysis measured a 94.6% recrystallization ratio, confirming that the high-aspect-ratio grain structure observed in as-printed samples was eliminated.Tensile testing of heat-treated samples showed that UTS values equalized across orientations, measuring 906.1 MPa and 879.2 MPa, while elongation reached 20.2% and 17.9%, respectively. The grain morphology shift reduced anisotropic effects, improving uniformity in mechanical performance.Powder Morphology and LPBF Processing Parameters. Image via Materials Futures.Following solution treatment, annealing at 450C for 0.5 hours introduced additional microstructural changes. TEM imaging identified nanoscale martensitic laths and annealing twins in the heat-treated samples. Kernel average misorientation (KAM) mapping confirmed that residual stress decreased significantly after treatment.Grain size analysis found that heat-treated samples retained slight anisotropy in grain diameter but eliminated elongation differences caused by grain morphology. X-ray diffraction (XRD) measurements showed that -FCC and -HCP phases remained stable following heat treatment, with no phase transformation detected.Residual Strength Reduction and Further Research ConsiderationsAlthough heat treatment eliminated anisotropic mechanical behavior, post-treatment samples exhibited reduced strength compared to as-printed CoCrMo alloys. Solution treatment removed columnar grain structures, while annealing introduced new strengthening mechanisms through precipitate formation and twin boundaries.Further research is required to evaluate how precipitate formation at grain boundaries influences long-term fracture behavior. The study did not examine wear resistance or fatigue properties, leaving open questions about how treated CoCrMo alloys perform under cyclic loads.Orientation and Phase Transformation. Image via Materials Futures.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.Anyer Tenorio LaraAnyer 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.