For decades, additive manufacturing firms have been dependent on a narrow pipeline of polymer powders. Alpha Powders, a Warsaw-based startup, aims to disrupt this dependence through spherodization, a processing technology that converts irregular, pulverized plastic particles into optimized spherical powders suitable for powder bed fusion printing. “Plastic was never meant to be pulverized,” said Dominik Zdybał, CEO of Alpha Powders. “It was meant to deform, be tough, not to break apart. The clue’s in the name.” Pulverizing plastic, typically through cryogenic methods, results in irregular particles with poor flow properties and high internal porosity. This is a critical issue in powder bed fusion applications where material uniformity and flowability are essential for part strength and repeatability. Alpha Powders’ core innovation lies in turning those irregular particles into spheroids. Their proprietary method modifies both shape and particle size distribution. In testing, the transformation yields uniform powders with reduced porosity, better flowability, and improved tensile strength in printed parts. “When you pour irregular powder into the machine, it emits a lot of harmful dust,” Zdybał explained. “That dust is something you want to avoid, not just for health and environmental reasons, but also because it can jam bearings and damage machines.” In contrast, their spherical powders are ergonomic to handle and reduce contamination risk, while also improving consistency during printing. The process supports a variety of advanced formulations. Alpha Powders is currently collaborating with equipment manufacturer Fisch Equipment to commercialize a carbon fiber-reinforced variant based on polyamide. Zdybał highlighted one formulation: a powder with 3 GPa stiffness and just 0.8 g/cm³ density, offering machinability alongside printability. “This is super lightweight material with very high stiffness,” he said. “It gives you the opportunity to print very lightweight, big parts with a nice surface finish.” Alpha Powders Foamide 3D printed sample. Photo by Michael Petch. Alpha Powders targets sustainable upcycling with patented spheroidization platform Alpha Powders is expanding the applicability of its patented spheroidization platform, offering a novel route to recycle and upcycle both waste plastics and spent powder from additive manufacturing processes. Pigmented for compatibility with diode laser systems and capable of handling diverse thermoplastics, the technology is already supporting applications from elastomers to structural composites. “Our powders are all pigmented because many systems use diode lasers,” explained Zdybał. “You can also get your hands on polyolefin-based material with very high elasticity and elongation at break. It’s based on inherently cheap feedstock.” The company’s system is not limited to virgin materials. It enables post-processing of waste powder from selective laser sintering (SLS), improving its flowability and rheology. The result is a higher-quality input than the original feedstock, positioning Alpha Powder’s approach firmly within the category of upcycling. “This is upcycling in its purest form,” said Zdybał, referring to a recent collaboration with Fishy Filaments. “That material—100 percent recycled fishing net—was floating in a Cornish Bay two years ago. Now, it’s being used with reclaimed carbon fibre to create a sustainable formulation.” The firm holds patents across key global markets, including the US, EU, China, Korea, and Japan, for its spheroidization process. The technology functions as a platform capable of treating a broad span of thermoplastics up to 260°C, including filled and pigmented composites, and fiber-reinforced materials. “This is pretty vast and pretty new,” Zdybał said. “You can work with carbon fibres or whatever else you want embedded in your grains.” The response at the AMUG Conference was unexpectedly unified, he noted. “Everyone is on the same page. Even if it’s their first time hearing about this method of upcycling and powder creation, they immediately get the point.” While Alpha Powders hinted at a significant upcoming project, Zdybał declined to disclose details. “The best things we cannot show,” he said. “But it’s going to be huge.” What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? 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 Alpha Powders Foamide sample. Photo by Michael Petch. Michael Petch Michael 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.

Velo3D, a U.S.-based metal 3D printer manufacturer, has entered into a five-year exclusive supply agreement with Amaero, Australian-based metal AM specialist, projected to generate approximately $22 million in revenue. Under the terms, Amaero will serve as Velo3D’s exclusive supplier for Niobium C103 and other refractory alloy powders—including molybdenum, tantalum, tungsten, and zirconium—and will be the preferred supplier for titanium alloy powders. Velo3D will also  qualify Amaero’s spherical powders and develop exclusive print parameters for both C103 and refractory alloys across all Velo3D Sapphire printers, as well as for Amaero’s titanium alloy powder on new machine sales. The print parameters will be included with the 3D printing machine licensing, without any extra charge to customers. Velo3D will use Amaero’s C103 and refractory alloy powders exclusively for all parts production, including its Rapid Production Solutions (RPS) initiative, and will dedicate a Sapphire machine to production with C103 powder. Velo3D will also dedicate a Sapphire XC machine to production with titanium alloys. Additionally, Velo3D will exclusively offer Amaero’s C103, refractory, and titanium alloy powders for sale to its 3D printing machine customers. The Sapphire family of printers. Image via Velo3D. Velo3D explained that this collaboration is a step toward supporting the re-shoring of advanced manufacturing to the United States.  Dr. Arun Jeldi, Velo3D’s CEO, commented: “Velo3D is very excited to enter a long-term supply agreement with Amaero and to extend our proprietary print parameters to include C103 and refractory alloy powders. As space and defense applications evolve to require materials that perform in very high temperature and extreme condition environments, a proficient capability to 3D print parts from C103 and refractory alloys is an important and differentiating capability.” Amaero’s Strategic Expansion and Commitment to U.S. Manufacturing Hank J. Holland, Chairman and CEO of Amaero, emphasized that strengthening and expanding U.S.-based advanced manufacturing and supply chain capabilities is central to the company’s strategy. He noted that after decades of offshoring, recent policy efforts—particularly under the Trump Administration—have reprioritized industrial policy to support both national security and economic growth. In response to critical vulnerabilities in the domestic supply chain, Amaero is making capital investments totaling approximately A$72 million through FY2026. This includes the commissioning of four state-of-the-art gas atomizers, expected to provide an annual powder production capacity exceeding 800 metric tonnes. The company has also allocated specialized production areas: one room and an EIGA Premium system for atomizing refractory alloys like niobium, molybdenum, tantalum, tungsten, and zirconium, and another planned for titanium alloy production, with the capability to scale up to five EIGA Premium atomizers. Refractory Powders. Photo via Amaero. “To achieve the potential of metal additive manufacturing, it’s important that we have a vibrant and financially strong domestic ecosystem that includes 3D printing OEM companies, high throughput and technically proficient part manufacturers and scalable, high quality, cost competitive spherical powders, “ said Holland. “We look forward to collaborating with Dr. Arun Jeldi and the Velo3D team to accelerate adoption of metal 3D printing and to improve the resiliency and scalability of domestic manufacturing.” Strategic Supply Chain Partnerships In March, PyroGenesis, a Canadian metal powder producer, officially confirmed Boeing as the aerospace OEM in its Ti64 metal powder qualification process, ending months of speculation. P. Peter Pascali, President and CEO of PyroGenesis, emphasized the significance of this achievement. “PyroGenesis is proud to be in the final queue for achieving supplier status with Boeing, one of the largest, most notable, and most advanced companies in the world. What’s exciting for PyroGenesis is that Boeing has shown itself to be a true innovator in the additive manufacturing arena, having spent more than three decades using 3D printed parts.” In February, Ireland-based Croom Medical and US-based tantalum products supplier Global Advanced Metals (GAM) have developed a closed-loop supply chain approach to expand the use of tantalum in 3D printing.  By tackling the material’s processing challenges and making its use more sustainable, the two companies are ensuring a steady, recyclable supply of tantalum powder for medical applications. Their process relies on Colibrium Additive’s M2 laser powder bed fusion (LPBF) technology to improve printing efficiency, making tantalum a more practical option for 3D printed implants. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows Refractory Powders. Photo via Amaero. Paloma Duran Paloma Duran holds a BA in International Relations and an MA in Journalism. Specializing in writing, podcasting, and content and event creation, she works across politics, energy, mining, and technology. With a passion for global trends, Paloma is particularly interested in the impact of technology like 3D printing on shaping our future.

The Australian Government has committed AUD$58 million to the establishment of the Additive Manufacturing Cooperative Research Centre (AMCRC), which is part of a broader AUD$271 million investment over the next seven years. The AMCRC aims to propel the growth of Australia’s manufacturing sector, boosting production processes and productivity through the advancement and application of AM technologies. This initiative will unite 101 partners across various sectors, including industry leaders like Boeing, over 70 small-to-medium enterprises (SMEs), three industry associations, 13 universities, and the CSIRO. In addition to advancing technological capabilities, the AMCRC is focused on contributing to key national objectives, such as enhancing industrial efficiency and supporting Australia’s transition to a net-zero economy. Targeted sectors for development include defence, aerospace, healthcare, automotive, and construction. “Over the last decade, AM has seen remarkable growth, driving advancements in 3D printing technology characterised by enhanced precision, scalability and material diversity. This evolution has shifted the AM landscape from targeted prototyping and small-scale production to full scale commercial production. It is now transforming industrial processes and supply chains, resulting in reduced lead times and material costs, ushering in a new era of efficient and sustainable manufacturing,” said Simon Marriott, Director and Bid Lead, AMCRC. Final Stage of the Additive Manufacturing CRC Bid. Photo via AMCRC. Industry Participation and Workforce Development Plans Matthew Wall, Additive Manufacturing and Innovation Lead at Boeing Aerostructures Australia, emphasized that the AMCRC will foster deeper collaboration between researchers and technology developers. “Boeing is committed to advancing AM technologies, recognising its pivotal role in the future of aerospace production. AMCRC will allow for greater collaboration with Australian technology developers and researchers to strengthen Australia’s AM capabilities for emerging technologies in the areas of AM tooling and materials,” Wall said. Boeing facility in Scotland. Photo via NMIS. The AMCRC initiative will also place a strong emphasis on workforce development, with AMTIL CEO and AMCRC Director, Lorraine Maxwell, underscoring that a highly skilled workforce will be pivotal to the success of the project.  “Australia’s AM researchers are ranked 5th globally, and with 13 universities and the CSIRO contributing to the AMCRC, there is immense potential for workforce development,” said Marriott. He pointed to the promise of industry-led PhD programs, increased student enrollment in undergraduate courses, and expanded access to vocational training as key drivers in cultivating a skilled workforce to meet the evolving demands of additive manufacturing. These efforts aim to ensure that Australia remains at the forefront of AM technology while creating a sustainable talent pipeline for the future. Governments Strengthen Additive Manufacturing Capabilities Last month, Germany’s coalition agreement between the Christian Democratic Union (CDU), Christian Social Union (CSU), and the Social Democratic Party (SPD) has formally included 3D printing among the technologies it plans to support in the upcoming legislative term. While brief and lacking specifics, the mention is a positive signal for the AM sector, aligning with broader government goals around industrial modernization, digital infrastructure, and climate policy. Industry stakeholders have long called for greater political support, and the inclusion suggests that AM is gaining recognition in national economic strategy. The move has been welcomed by Mobility goes Additive (MGA) e.V., a Berlin-based AM network representing over 140 members across the value chain, including companies like 3D Systems, BigRep, and Materialise. In 2024, the Manufacturing Technologies Association (MTA) also welcomed the new UK Labour Government’s focus on strengthening manufacturing and technology, including AM and Industry 4.0. Based in London, the MTA is the national trade association representing companies in the manufacturing technology sector. Following the 4 July 2024 general election, which ended 14 years of Conservative Party leadership, Prime Minister Keir Starmer outlined an industrial strategy focused on long-term planning and economic stability. Key initiatives include establishing a statutory Industrial Strategy Council with representation from all UK regions, businesses, and trade unions. 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 final Stage of the Additive Manufacturing CRC Bid. Photo via AMCRC.

After concluding the Markforged acquisition, Nano Dimension has reported full-year (FY) 2024 revenue of $57.8 million, a 2.6% increase from $56.3 million in FY 2023. Fourth-quarter (Q4) revenue reached $14.6 million, up 0.8% Y/Y from $14.5 million in Q4 2023. On a sequential basis, revenue was down by 1.9% from $14.9M in Q3’24. Gross profit for the year declined to $25.0 million, down 1.8% Y/Y, while Q4 gross profit was $4.9 million, a 31% decrease from $7.0 million in Q4 2023. Alongside these results, the company implemented structural changes, including a narrower product focus, a $20 million reduction in annual operating expenses, and a 52% increase in revenue per employee. This was driven by capital discipline and long-term profitability goals, despite a Purchasing Managers Index (PMI) below 50. “We’re shifting from chaos to discipline,” said CFO Assaf Zipori. He explained that cost reductions stemmed from a focused strategy and improved structural alignment, resulting in “formerly a bloated cost structure now materially reduced.” Sales growth in a challenging macro environment. Image via Nano Dimension. Aggressive expansion to focused execution  A lot can change in a year, and Nano Dimension’s trajectory is a clear example of that. The shift from then-CEO Yoav Stern to Ofir Baharav brought more than just a change in leadership; it signaled a broader transformation in tone, priorities, and direction. During the Q4 2023 earnings call, Stern presented a business focused on rapid growth and consolidation. He described 2023 as “a fantastic year for Nano Dimension,” citing a 29% revenue increase and improved gross margins.  Confident in the company’s significant cash position, he outlined a strategy based on acquisitions, saying, “If we end up with $10 million, 12 million cash burn a year, with $1 billion in cash, which is going to be used for acquisitions and for R&D, we’re in an excellent, excellent shape. Stern’s message was forward-looking and ambitious. He highlighted customers such as NASA and the U.S. Department of Defense and emphasized Nano’s role in what he called a business domain, rather than conventional industry. Software development and AM innovation featured heavily in his narrative. Fast forward to the Q4 2024 earnings call, Baharav’s tone was more grounded. He described 2024 as “a year of transformation,” shaped by execution and financial fundamentals. The company exited non-core units including Admatec, DeepCube, Formatec, and Fabrica as highlighted in a letter to shareholders by activist investor Murchinson. This move helped Nano reduce operating costs by $20 million, and focus on profitability. That shift was echoed by CFO Assaf Zipori, who said, “Efficiency matters. We have already made big changes and we don’t plan to stop.” The team highlighted a major increase in revenue per employee (from $147,000 to $223,000) as a result of structural improvements rather than staff expansion. Unlike Stern’s abstract vision, Baharav emphasized tangible, measurable results. Both leaders acknowledged the importance of software, but with contrasting approaches. Stern discussed its potential to reshape the industry, while Baharav focused on Markforged’s platform as a near-term asset within a focused investment strategy. Taken together, the calls reflect a company moving from aggressive expansion to focused execution, shifting its priority from scale to sustainability. Update on Desktop Metal and Markforged Alongside its internal overhaul, Nano Dimension has begun reviewing its acquisitions, particularly Desktop Metal and Markforged. Both are under strategic assessment to determine how they fit into the company’s long-term vision. Markforged is viewed as a strong asset for its software and broad installed base, while Desktop Metal raises financial concerns. CFO Assaf Zipori explained that the acquisition was completed under court order, with Nano paying nearly $180 million to Desktop Metal shareholders. The company has since provided limited secured financing to support short-term obligations but has not committed to any additional funding. Zipori addressed the situation directly, calling Desktop Metal “the elephant in the room.” He noted that the company faces significant financial liabilities, including $115 million in outstanding convertible notes, all incurred prior to the acquisition. He reiterated that any further involvement would depend on clear strategic fit. Internally, leadership said site visits revealed new cost-saving opportunities and ways to align operations. These observations informed decisions to consolidate roles and streamline offerings. According to management, this cultural reset aimed not only to improve margins but to unlock innovation by reducing organizational friction. By simplifying structure and holding teams accountable to profitability metrics, Nano believes it is now better equipped to deliver complex, high-performance parts across key sectors. Nano Dimension 3D printed electronics on display at RAPID + TCT 2024. Photo by 3D Printing Industry. Guidance for FY 2025 Though the company did not issue formal guidance for FY 2025, it shared preliminary figures. Q1 2025 revenue is expected to reach $14.4 million, up 8% from the prior year. Cash and cash equivalents stood at around $840 million as of March 31, 2025, excluding contributions from Q2 acquisitions. Leadership emphasized that future investments, including further involvement with Desktop Metal, will be evaluated based on their alignment with Nano Dimension’s focus on margin improvement and shareholder value. Management expects to have clarity on Desktop Metal’s strategic review by the end of June. Looking ahead, the company plans to strengthen its presence in four core markets: aerospace and defense, automotive, electronics, and medical. These sectors align with Nano Dimension’s core capabilities and the growing demand for complex, high-performance parts. Bringing the call to a close, executives noted that with transformation underway and strategic priorities now clarified, FY 2025 is expected to be defined by disciplined execution and measurable outcomes. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows sales growth in a challenging macro environment. Image via Nano Dimension.

As metal additive manufacturing scales from prototyping to serial production, powder quality demands are intensifying. At m4p Material Solutions, that means going far beyond standard compliance. From tightening tolerances on sphericity and alloy composition to developing in-house methods for detecting microscopic contamination, the company is positioning itself at the frontier of reliable, production-grade materials supply. m4p Targets AM Maturity With Agile Materials Portfolio and Processing Warnings Speaking at the 2025 AMUG Conference, Burghardt Klöden, Global Sales Director at m4p Material Solutions, is blunt about what the additive manufacturing sector still lacks: maturity. “We believe the AM ecosystem still needs some growth,” he said. “We help people get started and ideally, grow together.” The company, founded ten years ago, has scaled rapidly, surpassing triple-digit customer counts and tripling revenue since its inception. Its core value proposition is responsiveness (90% of deliveries are made within one to three days) and technical flexibility, supporting all powder-based AM technologies initially with small minimum order quantities, then large quantities as usage increases. The materials portfolio is divided into three categories: standard materials (just over one-third), development products (about 40%), and customized materials tailored to client specifications (around one-quarter). The development products are typically co-created with R&D or industrial partners and include several proprietary or licensed alloys. Resisting Limits: A High-Temp Aluminum Alloy One of m4p’s recent highlights is a high-temperature aluminum alloy known as ResistAl, originally developed externally and licensed into their portfolio. “At the time, it was really unique,” Klöden said. The material targets applications such as aerospace and motorsports, offering impressive strength retention at elevated temperatures without requiring post-build heat treatment. ResistAl is a multi-phase alloy with notable high-temperature microstructural stability. Klöden explained that the yield strength remains virtually unchanged even after 200 hours of artificial aging at 250°C. “No major change in microstructure, even after artificial heat treatment. This makes this alloy pretty special,” he said. However, this performance comes at a cost, “This material is very challenging to process.” To achieve the advertised mechanical properties, samples must be printed on specialized machines equipped with heated build plates reaching 350°C. Despite this, m4p’s customers are pushing boundaries. A French R&D partner recently managed to print ResistAl on a standard AM machine, a breakthrough Klöden characterized as both impressive and unlikely without deep process expertise. The customer was able to 3D print a complex component with lattice structures and no signs of delamination, a task m4p had previously failed using the same setup. “If you do it right, there is a good chance you are rewarded with outstanding properties,” he noted. Iron-Based Versatility and Unexpected Consumer Use The company’s iron-based alloy portfolio includes several grades tailored for specific industrial segments, from oil and gas to high-displacement automotive components. One material Klöden highlighted, based on a 6+ iron alloy, combines the hardness of martensitic structures with the corrosion resistance of austenitic types. The properties can be tuned via heat treatment, offering high tensile strength and modifiable elongation. A particularly unconventional case study involved a consumer product: tailor-made knives. A customer used the 6+ alloy to produce durable, customized blades with engraved handles, leveraging AM’s design freedom and material hardness to differentiate their offering. Though far from m4p’s core industrial clientele, the example underscored the flexibility of their materials platform. As m4p’s customers shift from prototyping to serial production, their expectations shift accordingly. Klöden emphasized that powder consistency, particularly flowability and spreading behavior, becomes increasingly critical. “In prototyping, you can make up for some failed parts,” he said. “In serial production, this gets much more critical.” Larger build volumes introduce higher risks of part failure during the build or post-processing stages. m4p has responded by ensuring their powders meet tight specifications on parameters such as particle size distribution and morphology. While the former is commonly reported on certificates of analysis, the latter (linked to powder sphericity and flow characteristics) is not, though it directly affects build quality. Advanced Powder Testing for Metal Additive Manufacturing Ensuring consistent material performance in additive manufacturing requires more than meeting specifications. Fittingly, m4p has moved beyond a compliance mindset toward proactive control of variability across batches. “Don’t max out what you’re given by the spec,” he said. “This leads to instability in processing.” Using Ti-6Al-4V as an example, Klöden detailed how m4p applies tighter internal controls than industry standards demand, particularly for particle morphology and chemical composition. Sphericity is measured using image analysis that evaluates the ratio between a particle’s major and minor axes. “A ratio of 0.9 is already quite close to ideal,” he noted, “and we monitor how much of our powder stays above that threshold.” This level of control also applies to elemental composition. Klöden displayed data from multiple years of titanium alloy production, showing how the company maintains a consistent aluminum concentration near the lower end of the acceptable range. “It’s not easy, but it’s well managed,” he said. A Structured Approach to Quality While many powder suppliers address morphology and particle size distribution (PSD), contamination remains poorly standardized. M4p’s Priyanshu Bajaj explained, “There’s no existing ISO or ASTM standard that defines a repeatable method to quantify contamination in metal powders.” To fill this gap, m4p has developed its own methodology, built around scanning electron microscopy (SEM) paired with energy-dispersive X-ray spectroscopy (EDS). This enables both visual detection and elemental classification of unwanted particles. “The moment you add anything that’s dissimilar and undesired, for example, plastic fragments or foreign metals, that’s contamination,” said Bajaj. “Even if it’s small, even if it’s rare, it can cause problems.” Because such contamination is often invisible to standard chemical assays or PSD reports, m4p adapted pharmaceutical-grade sampling techniques to ensure statistical relevance. Powders are sampled and prepared for SEM inspection using an automated platform and image analysis software. EDS is then used on identified outliers to determine their composition. One customer returned a batch after experiencing unexpected part failures. The SEM-EDS process revealed the presence of sub-5-micron cobalt-based particles, well below the detection limits of conventional analysis, but sufficient to affect downstream performance. “You wouldn’t catch this with standard methods,” the team said. “But it’s enough to cause real trouble in production.” m4p’s statistical approach to contamination testing. Photo by Michael Petch. What Happens When Contamination Is Detected? Asked about next steps after identifying contamination, the company clarified that while rejecting a batch is sometimes necessary, other options exist. “It depends on the nature of the contamination,” they said. “We assess whether cleaning or powder reclamation is viable. If not, we discard the batch.” The team stressed that this level of scrutiny is part of standard procedure for all outgoing shipments. With contamination rates below 2 percent by particle count, most of them smaller than five microns, m4p positions itself as a supplier prepared for the stringent reliability needs of serial production environments. The company’s message to customers is clear: robust quality control requires more than trusting what’s on the certificate of analysis. It requires ongoing inspection, tight tolerances, and an active risk management strategy: before the powder ever touches the machine. The takeaway from m4p’s approach is that consistent powder performance cannot be left to certificates of analysis alone. Real stability comes from controlling what lies between the lines of a spec sheet: subtle variations in particle shape, contamination undetectable by routine tests, and long-term drift in composition. With an eye on data, automation, and pharmaceutical rigor, m4p is making the case that materials excellence is an operational discipline. This is critical to AM’s shift into mature manufacturing. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? 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 Burghardt Klöden, Global Sales Director at m4p Material Solutions. Photo by Michael Petch. Michael Petch Michael 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.

Simulation is emerging as a vital tool for controlling the complex physics of metal additive manufacturing, as engineers seek to improve process reliability and reduce defects. Speaking during the 2025 AMUG Conference, Garrett Clyma, a computational fluid dynamics (CFD) engineer at Flow Science, Inc, outlined how melt pool modeling is providing new capabilities to optimize laser processes without the prohibitive costs of physical experimentation. At the heart of the challenge lies the highly localized heating and rapid cooling of metals during AM. Instabilities in the melt pool caused by overheating or underheating result in defects such as porosity, incomplete fusion, and surface irregularities. “Controlling the material behavior in AM is very challenging because of the complexity of all these different interactions of the individual physics,” Clyma explained. FLOW-3D AM, is a multi-physics CFD platform designed to capture these phenomena with high fidelity, enabling engineers to visualize the evolution of melt pool instabilities and preempt defects before committing to costly build experiments. Garrett Clyma from Flow Science. Photo by Michael Petch. Beam Shaping: A Tool for Process Stability Laser beam shaping, an established practice in welding, is gaining ground in AM as a method to tailor the spatial energy distribution of the beam. Rather than relying on the traditional Gaussian profile, beam shaping distributes energy more evenly or selectively across the beam, influencing melt pool behavior and solidification characteristics. Clyma presented the findings of a study conducted by Dr. Mohamed Bayat’s group at the Technical University of Denmark, which used FLOW-3D AM to investigate ring beam profiles applied to single-track titanium alloy builds. Validation against both cross-sectional cuts and in-situ X-ray monitoring demonstrated strong alignment between simulation and experiment, with melt pool dimension errors well under 10 percent. As the team varied the ratio of core-to-ring power while maintaining constant total laser energy, the simulations revealed clear trends. Ring beams produced wider, shallower melt pools, avoiding the deep keyholes characteristic of Gaussian beams. “The ring beam creates a substantially smaller, less deep annular depression zone, which results in a more stable melt pool,” Clyma said. At higher laser powers, however, instabilities resurfaced. Simulations predicted the formation of elongated molten jets and spatter ejection from the melt pool—behaviors that were subsequently confirmed by high-speed X-ray imaging. Simulated and in-situ experimental melt pool profile in Exploring spatial beam shaping in laser powder bed fusion: High-fidelity simulation and in-situ monitoring. Image via Elsevier. Expanding to Arbitrary Beam Shapes Building on these results, Flow Science conducted an internal study exploring both static and dynamically shaped laser beams, including complex profiles such as infinity patterns, spirals, and five-dot arrays. Running on a 10-core desktop machine, individual simulations generally completed in under six hours, while recent parallelization developments have enabled even larger parametric sweeps. The five-dots configuration, for example, concentrated energy at discrete points, producing high penetration depths under keyhole mode conditions but limited effectiveness in conduction mode. “We’re not efficiently heating up the melt pool, but just heating up these single points,” Clyma explained, emphasizing that beam selection must align with the intended mode of operation. Lower maximum melt pool velocities and more uniform temperature distributions observed in spiral and infinity patterns suggested that these shapes could offer better process stability than concentrated beams. Across all cases, metrics such as intensity, temperature, melt pool velocity, and processing rate provided a consistent framework to evaluate trade-offs before moving to physical trials. “Simulation is a very useful tool for helping to make those decisions,” Clyma said, noting that the growing degrees of freedom in laser control require systematic methods to identify promising beam strategies. A visualization of Laser Powder Bed Fusion Simulation. Image via Flow Science. Surface Tension, Optical Effects, and Material Dependence AMUG Conference attendees raised detailed questions about the extent of physics modeled within FLOW-3D AM. Clyma confirmed that key factors such as temperature-dependent surface tension, contact angle, and laser absorptivity are incorporated into simulations. Absorptivity, often lacking in published material datasets, can be adjusted as a tuning parameter when required. Thermo-physical properties are typically sourced from databases such as JMatPro, allowing simulations to reflect the specific behavior of alloys under melt conditions. Accurate modeling of laser reflections and multi-bounce phenomena is also supported. A participant complimented the strong agreement between simulation predictions and experimental observations, particularly in melt pool shape, spatter formation, and transition between conduction and keyhole modes. Practical Trade-offs: Stability Versus Penetration The session concluded with a discussion of how different beam profiles affect not only defect formation but also material properties. While Gaussian beams enable deeper penetration and potentially finer grain structures due to steeper thermal gradients, they also introduce higher risks of spatter and porosity. In contrast, ring beams offer enhanced stability and reduced peak temperatures, but may alter solidification patterns. “It really just depends on your intended goal,” Clyma said. “If you’re able to explore the effects in simulation rather than experimentation, it can be a lot more advantageous.” FLOW-3D AM provides outputs such as temperature gradients and cooling rates, which are primary drivers of microstructural evolution. Although the software does not yet predict mechanical properties directly, these outputs enable users to infer likely outcomes such as grain size, elongation, and impact resistance. Another engineer elaborated that finer, more oriented grains (arising from high gradients and rapid cooling) often correlate with improved mechanical properties. FLOW-3D AM’s cell-level resolution, often at five million elements or finer, allows for detailed local analysis of these solidification dynamics. As simulation capabilities continue to expand, AM engineers now have a powerful toolkit to optimize laser processing strategies, reduce defects, and enhance the performance of printed metal parts: all before pressing “print” on a machine. What 3D Printing Trends are shaping the industry? Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news. You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry YouTube channel to access more exclusive content. Featured image shows a visualization of Laser Powder Bed Fusion Simulation. Image via Flow Science. Michael Petch Michael 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.

AML3D Limited, a company specializing in Wire Additive Manufacturing (WAM) and 3D metal printing solutions, has released its Quarterly Activities Report for the period ending 31 March 2025 (Q3FY25). The company reported break-even operating cash flow during the quarter, driven by A$2.5 million in customer receipts, supported by growth in the US market.  As of 31 March 2025, the company’s cash reserves stood at A$31.4 million, positioning AML3D to pursue its next phase of growth, which includes a A$12 million plan to scale up US production and a A$5 million investment to enter the European market. ARCEMY 2600 Small Edition 3D printer. Photo via AML3D. U.S. Market Expansion AML3D’s expansion in the US is positioned to meet rising demand, especially from the US Department of Defense and other industries. With the addition of a second ARCEMY large-scale Wire Additive Manufacturing system and the establishment of a manufacturing and technology hub in Ohio, the company is strengthening its presence in the US market.  This growth is further supported by a US$951 million award from the Department of Defense to Blue Forge Alliance (BFA) in early 2025, aimed at advancing manufacturing technologies for the US Navy‘s submarine industrial base. The company is providing ARCEMY systems to support the Navy’s submarine base, including the largest custom ARCEMY system ever installed at the Navy’s Daneville Centre of Excellence for Additive Manufacturing, managed by AUSTAL USA. During a 14-day tour across 10 US sites in the March 2025 quarter, CEO Sean Ebert met with US Senators, defense and industry partners. AML3D’s success with ARCEMY technology in the US Navy’s submarine industrial base positions the company to explore further additive manufacturing contracts across the US Navy marine industrial base. In addition to defense, AML3D is expanding into non-defense sectors such as utilities, aerospace, marine, and oil & gas. The company is fulfilling in A$2.27 million ARCEMY X order for the Tennessee Valley Authority (TVA), the largest US public utility, to support its power generation repair capabilities, with final commissioning set for the first half of 2026. AML3D has also delivered non-defense test components for Boeing and Chevron and holds a Manufacturing License Agreement with Boeing Defence and Space. The company’s AS9100D certification for aviation, space, and defense manufacturing was reaffirmed during a surveillance audit completed in March 2025. A large 3D printed shipbuilding component. Photo via AML3D. European, Australian Expansion AML3D is also focusing on expanding into the European market, initially targeting the UK defence sector. The company has signed a material feasibility contract with a tier-one UK defence contractor, marking the beginning of its efforts in the region. AML3D plans to replicate its successful US strategy by appointing a distributor and focusing on defence, with plans to explore additional opportunities in industries such as aerospace, marine, and oil and gas across Europe. In Australia, AML3D continues to support the defence sector by providing marine and aerospace test parts for the Defence Science and Technology Group. The company is also working on prototype components for BAE Systems Maritime Australia’s Hunter Class frigate program. These activities are expected to contribute to the company’s growth within the Australian defence sector, while AML3D is also exploring potential non-defence opportunities. One of the hunter class frigates. Photo via AML3D. Research and Development Investment AML3D is focused on advancing its technology through research and development investments. During the quarter, the company allocated half of its A$700,000 property, plant, and equipment investment to the ARCEMY Increased Deposition Rate (AIDR) project and the construction of a prototype AIDR system, which aims to increase the speed of component production. The South Australian Government has provided A$186,000 as part of the A$2.24 million funding agreement for this AIDR project. Financial Update and Outlook AML3D reported A$2.5 million in customer receipts for the March 2025 quarter, a 37% increase compared to the same period last year, including A$1 million in overdue payments from the previous quarter. The company’s strong cash position of A$31.4 million provides a solid foundation for continued investment in its US and European expansion efforts.  Looking ahead, AML3D is focused on furthering its work in the US defence sector and exploring new opportunities across both defence and non-defence markets. 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.one of the hunter class frigates. Photo via AML3D. Featured image  Paloma Duran Paloma Duran holds a BA in International Relations and an MA in Journalism. Specializing in writing, podcasting, and content and event creation, she works across politics, energy, mining, and technology. With a passion for global trends, Paloma is particularly interested in the impact of technology like 3D printing on shaping our future.

Conflux Technology, an Australian firm renowned for its metal 3D printed heat exchangers, has announced the opening of its first European hub in the United Kingdom. The new facility marks a key step in Conflux’s international growth strategy and is set to boost support for European customers across sectors such as aerospace, automotive, energy, defence, and e-mobility. Scheduled to open later this quarter, the UK hub will initially focus on research and development, materials certification, and addressing local supply chain constraints. In time, Conflux plans to evolve the site into a full-scale production centre as regional demand continues to grow. The expansion underlines the company’s commitment to building resilience and responsiveness in global supply chains. Founded in Melbourne in 2015, Conflux has spent the past decade redefining thermal management through additive manufacturing. Its proprietary Conflux Production System combines thermo-fluid design expertise with advanced metal 3D printing to create compact, lightweight heat exchangers engineered for high-performance environments. These capabilities have enabled Conflux to support industries where space, weight, and efficiency are critical, from Formula 1 racing to cutting-edge aerospace and energy systems. Europe has become a vital market for Conflux, representing more than a third of its overall business. The company already collaborates with prominent organizations such as Rocket Factory Augsburg, AMCM, and several Formula 1 teams. The new UK site is intended to deepen these relationships while providing localized technical support and accelerating product development cycles. Conflux manufacturing floor in Australia. Photo via Conflux. Continued Momentum and Sector Leadership The new hub follows a period of rapid advancement for Conflux. In 2023, the company secured $11 million in Series B funding to scale its operations and accelerate commercialization. It has since launched a cartridge-style heat exchanger targeting hydrogen and e-mobility markets, and entered into high-profile collaborations such as supplying thermal components for Rocket Factory Augsburg’s orbital rockets. Additionally, Conflux’s heat exchangers will be used in the hydrogen-powered Vertiia VTOL aircraft, a project highlighting the company’s expanding role in sustainable aviation technologies. A Decade of Innovation and Strategic Growth The UK expansion coincides with Conflux’s 10th anniversary, a milestone that reflects the company’s sustained innovation and industry impact. From its roots in Australia to an increasingly global footprint, Conflux has built a reputation for pushing the boundaries of heat exchanger design using additive manufacturing technology. Its focus on high-performance, scalable solutions has positioned it as a leader in the evolving thermal management landscape. “We are extremely proud to celebrate ten years of spearheading transformation in heat exchanger technology for superior performance with such a significant milestone,” said Michael Fuller, CEO and Founder of Conflux Technology. “Europe is a key market for us, Conflux UK will not only shape the future of the automotive, motorsport and aerospace markets, but also establish supply chain resilience, so we’re excited and ready to expand our operations and work closer with some truly innovative companies.” .What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? 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.Feature image shows Conflux manufacturing in Australia. Image via Conflux.

The University of Oklahoma (OU) and Oak Ridge National Laboratory (ORNL), US Department of Energy’s largest multi-program science and energy laboratory, have formed a strategic partnership to establish an advanced metal additive manufacturing center in Norman, Oklahoma. The effort is a joint initiative of OU’s Oklahoma Aerospace and Defense Innovation Institute (OADII), the OU’s Gallogly College of Engineering, and ORNL.  The center will combine the capabilities of OU’s Sooner Advanced Manufacturing Laboratory and ORNL’s Manufacturing Demonstration Facility to develop technologies for aerospace and defense, focusing on metal and hybrid additive manufacturing, research, machining, data analytics, and workforce training. “This long-term partnership with Oak Ridge National Laboratory fully aligns with the recently published update of OU’s strategic plan,” said Gen Robin Rand (USAF, ret.), OADII’s Executive Director. “Our deliberate push to advance additive manufacturing research is fueling innovation and economic prosperity in Oklahoma and reducing risk to our nation’s defense.” Representatives from the University of Oklahoma (OU) and Oak Ridge National Laboratory (ORNL) reach an agreement. Photo via OU. Defense Applications and Research Integration Through OADII and the Gallogly College of Engineering, the center will contribute to sustainment and mission readiness at Tinker Air Force Base and other regional military facilities, including the Air Force Sustainment Center and the Air Force Research Laboratory. It is intended to support Department of Defense objectives such as modernization and lifecycle maintenance of defense systems. ORNL will apply its expertise in managing the Manufacturing Demonstration Facility to support the development and implementation of advanced manufacturing processes. Meanwhile, OU will contribute academic resources, engineering expertise, and student involvement to support innovation and practical applications. “This partnership between OU and ORNL will have a substantial impact on our national security, particularly by advancing qualified additive manufacturing processes for the sustainment and readiness of the U.S. Air Force assets,” said Moe Khaleel, ORNL Associate Laboratory Director for National Security Sciences. “When the great people at our two institutions get together, with our collective resources, we will do big things for the nation.” Inside an aircraft. Photo via Air Force Rapid Sustainment Office. Enhancing Defense Capabilities through Additive Manufacturing Oklahoma is not alone in its commitment to strengthening defense capabilities through additive manufacturing (AM) and new partnerships. This month, Spanish 3D technology provider Sicnova officially launched the Center for Special Applications and Process Certification for the Military and Defense Sectors (CEDAEC), the first facility of its kind in Spain, dedicated exclusively to advanced manufacturing and the certification of components for the defense sector. The inauguration took place on April 4th at Novaindef’s facilities, renowned for their expertise in producing and securing critical defense components. In 2024, Additive manufacturing software company 1000 Kelvin partnered with Norwegian Defence Research Establishment (FFI) spin-off Fieldmade to enable the rapid deployment of 3D printers in active combat zones.   Announced during the Military Additive Manufacturing (MilAM) summit and technology showcase, this collaboration seeks to enhance strategic readiness and operational capabilities in the military sector.   This partnership allows 1000 Kelvin’s AMAIZE platform to be integrated with Fieldmade’s deployable additive manufacturing solutions, including its NOMAD series of transportable 3D printing modules.  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 imagerepresentatives from the University of Oklahoma (OU) and Oak Ridge National Laboratory (ORNL) reach an agreement. Photo via OU.

INTAMSYS, a high-performance polymer 3D printer manufacturer based in Shanghai, has launched version 25.1.0 of its slicing software INTAMSuite NEO. The latest update introduces a redesigned user interface and broadens material and printer compatibility, aiming to improve the user experience across industrial additive manufacturing workflows. The release includes a new startup assistant, updated toolpaths for optimized slicing, and support for recent material profiles developed in collaboration with partners. It also extends compatibility to new printer models including the FUNMAT PRO 310 and FUNMAT PRO 610HT, INTAMSYS’ industrial-grade machines known for handling high-temperature thermoplastics such as PEEK, PEKK, and ULTEM. The INTAMSYS FUNMAT PRO 310 NEO 3D printer. Photo via INTAMSYS. Workflow enhancements and new features One of the key improvements in INTAMSuite NEO 25.1.0 is a refreshed user interface that supports both light and dark modes, alongside a simplified printer setup wizard. The updated experience is designed to ease the onboarding process for new users and speed up print preparation for experienced operators. New slicing algorithms have also been introduced, resulting in more efficient toolpaths and improved support generation. For engineers working in aerospace, automotive, and medical sectors, where part quality and dimensional accuracy are critical, these refinements can help reduce both print time and post-processing labor. Additionally, INTAMSuite NEO now includes a built-in firmware updater and diagnostics dashboard for INTAMSYS printers, offering greater control and oversight for production environments. Material integration and ecosystem development The software update reflects INTAMSYS’ continued effort to strengthen its ecosystem of hardware, software, and materials. With INTAMSuite NEO 25.1.0, users can access validated print profiles for an expanded range of high-performance filaments. These include proprietary materials as well as those developed in cooperation with industry partners, addressing the growing demand for certified solutions in regulated industries. The integration of these profiles helps ensure repeatability and reliability for functional parts, especially in applications requiring flame retardancy, chemical resistance, or high mechanical strength. INTAMSuite NEO model analysis & repair wordspace. Image via INTAMSYS. INTAMSYS expands industrial 3D printing ecosystem with real-world applications The latest software update follows a series of developments across INTAMSYS’ hardware and industrial partnerships. In 2022, the company’s FUNMAT PRO 410 was reviewed for its high-temperature dual-extrusion capabilities and enclosed heated chamber, positioning it as a strong contender in the engineering-grade materials segment. More recently, Schneider Electric adopted the FUNMAT PRO 310 NEO to produce tooling up to seven times faster than conventional methods, demonstrating the printer’s value in accelerating factory-floor innovation. Additionally, INTAMSYS’ role in enhancing satellite production through precision polymer 3D printing has underscored its broader industrial relevance, especially in space and aerospace sectors where lightweight, high-performance components are critical. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? 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 INTAMSuite NEO interface. Image via INTAMSYS. Rodolfo Hernandez Rodolfo Hernández 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.

US-based biotechnology company Continuity Biosciences has invested in 3D printed microneedle technology specialist PinPrint to expand its focus from therapeutic delivery into aesthetic and cosmetic applications.  Designed to deliver vaccines and active agents intradermally, PinPrint’s microneedle patches offer a potential alternative to traditional injections. With this investment, Continuity aims to enhance its capabilities in the drug delivery sector. The company is also working with the Grattoni Lab at Houston Methodist Hospital to develop implanted nanofluidic platforms for extended, zero-order release. Additionally, Dr. Venugopalan is set to join PinPrint’s Board of Directors (BoD). “This investment allows us to expand from implanted nanofluidic systems to a non-implanted microfluidic platform,” said Ramakrishna Venugopalan, PhD, Co-Founder and CEO of Continuity Biosciences.  “It opens up new possibilities for more effective delivery of dermatologic, aesthetic, and cosmetic agents directly into the dermis,” Venugopalan said. Microfluidic enabled microneedle patch. Image via PNAS. Over-curing problem solved with iCLIP PinPrint was co-founded by Dr. Joseph DeSimone, Co-founder and former CEO of California-based 3D printer manufacturer Carbon. Alongside Stanford University researchers, DeSimone developed a 3D printing method that addresses resin over-curing, a challenge that hinders the precise construction of microchannels and voids in medical devices like microfluidic-backed microneedles. The technology behind PinPrint’s approach is based on this resin 3D printing process. Last year, their research was published in Proceedings of the National Academy of Sciences (PNAS) journal, introducing the injection CLIP (iCLIP) method. iCLIP improves the resolution and precision of 3D printed microfluidic devices by continuously feeding fresh resin into negative spaces during printing, preventing over-curing and ensuring a more accurate structure. Unlike traditional 3D printing methods, which struggle with over-curing that can distort the printed channels, iCLIP ensures that fresh resin fills these spaces, maintaining both the integrity and precision of the print. This ability to control resin flow leads to the creation of microchannels with smaller diameters and heights, enhancing the functionality of printed devices. The iCLIP methods is especially valuable in applications requiring high precision, such as drug delivery and biomedical devices. For example, its microneedle patches aim to improve the delivery of vaccines and therapeutic agents.  The iCLIP method allows PinPrint to produce smaller, more accurate devices, improving the delivery of treatments while offering non-invasive alternatives to traditional injection methods. Beyond microneedles, the iCLIP method has broad potential applications in areas like vascular networks, microarrays, and diagnostic devices. PinPrint is working to expand its portfolio of products using iCLIP, with a focus on biomedical and pharmaceutical uses. This method promises more efficient drug delivery systems, providing alternatives to current methods. “By integrating high-resolution 3D printing with advanced drug delivery, we’re redefining the patient experience across therapeutic and cosmetic categories—offering a new standard for precision, personalization, and comfort,” said Dr. DeSimone, currently Sanjiv Sam Gambhir Professor of Translational Medicine and Chemical Engineering at Stanford. Expanding microfluidic capabilities While PinPrint advances resin 3D printing for biomedical use, other companies are also tackling microfluidic manufacturing challenges through complementary approaches. In 2023, Canadian 3D printer manufacturer CADworks3D introduced a unique way to fabricating PDMS devices for microfluidic applications. Having integrated 3D printing with specialized photopolymer materials, the company has created a more efficient process for producing high-precision microfluidic devices.  A peeled PDMS device fabricated with CADworks3D’s 3D printed master mold. Photo via CADworks3D. With its ProFluidics 285D Digital Light Processing (DLP) 3D printer and Master Mold for PDMS Device resin, CADworks3D enables researchers the ability to quickly prototype and customize complex microstructures. This development enhances the soft lithography workflow, reducing production time and costs while delivering superior device features. The result is a faster, more accessible method for creating tailored microfluidic solutions. Through software, Microlight3D and Eden Tech aim to offer advanced microfluidic design tools for the healthcare, diagnostics, and research sectors. Combining Microlight3D’s Smart Print UV with Eden Tech’s FLUI’DEVICE design platform, this move is said to reduce design cycles, cutting them by up to 90% compared to traditional CAD methods.  The new solution enhances the accessibility, customization, and scalability of microfluidic devices. It enables quicker design iterations, lowers production costs, and ensures smooth integration with manufacturing systems. This partnership offers a novel tool for both academic and industrial users, streamlining workflows and accelerating time-to-market. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows microfluidic enabled microneedle patch. Image via PNAS.

U.S. tech company Hugging Face, in collaboration with French robotics developer The Robot Studio,  robotics store WowRobo, robotics part seller PartaBot and Chinese IoT hardware supplier Seeed Studio, has unveiled the SO-ARM101—the latest addition to its open-source, 3D printable robotic arm series. Designed for hands-on experimentation in reinforcement learning and imitation learning, the SO-ARM101 is part of the broader SO-ARM10x platform, which includes the earlier SO-ARM100. The system integrates with Hugging Face’s LeRobot framework—a PyTorch-based toolkit for robotic AI development—and aims to provide a low-cost, accessible hardware option for AI research and training. “Building on top of the insanely successful SO-100 (the most popular robot arms ever?), SO-101 are the first robot arms any AI builder should buy.  It costs from $100 to $500 depending on how much you want it assembled and your country of shipping. Can’t wait to see what you all build with it. Let’s go open-source affordable AI robotics!,” said Clément Delangue, Co-founder & CEO, Hugging Face. Key upgrades in the SO-ARM101 include a redesigned wiring system to prevent disconnection issues at joint 3, as well as mechanical changes that improve range of motion. The leader arm now uses motors with optimized gear ratios, eliminating the need for external gearboxes. Additionally, real-time synchronization between the leader and follower arms enables human-in-the-loop learning, allowing users to guide or adjust robot movements during training. SO-ARM101 Robotic Arm. Photo via: Hugging Face. Platform Features and Use Cases The SO-ARM10x series is supported by a full suite of open-source resources, including assembly instructions, calibration tools, data collection guides, and deployment documentation. The arms are compatible with NVIDIA’s reComputer Mini J4012 Orin NX 16GB, making them suitable for edge-based AI training and on-device inference. Through the LeRobot framework, users can simulate, train, and deploy models for physical tasks such as object manipulation, grasping, and placement. These workflows are intended to help users iterate quickly on AI model development in real-world settings. Community support is available via GitHub and Discord, where technical documentation and updates are maintained. SO-ARM101 Arm Kit. Photo via: Seeed Studio. System Overview and Technical Specifications The SO-ARM101 shares its architecture with the earlier SO-ARM100 but includes targeted improvements for performance and reliability. The following table outlines key specifications: FeatureSO-ARM100 Arm KitSO-ARM100 Arm Kit ProSO-ARM101 Arm KitSO-ARM101 Arm Kit ProLeader Arm Configuration12× 7.4V 1:345 gear ratio motors (all joints)12× 12V 1:345 gear ratio motors (all joints)1× 7.4V 1:345 motor (Joint No.2)2× 7.4V 1:191 motors (Joints No.1 & No.3)3× 7.4V 1:145 motors (Joints No.4, No.5 & gripper)1× 7.4V 1:345 motor (Joint No.2)2× 7.4V 1:191 motors (Joints No.1 & No.3)3× 7.4V 1:145 motors (Joints No.4, No.5 & gripper) Power Supply5.5mm×2.1mm DC 5V 4A5.5mm×2.1mm DC 12V 2A5.5mm×2.1mm DC 5V 4AFollower Arm: 5.5mm×2.1mm DC 12V 2ALeader Arm: 5.5mm×2.1mm DC 5V 4AAngle Sensor12-bit magnetic encoder12-bit magnetic encoder12-bit magnetic encoder12-bit magnetic encoderOperating Temperature0℃ – 40℃0℃ – 40℃0℃ – 40℃0℃ – 40℃Communication MethodUARTUARTUARTUARTControl MethodPCPCPCPC The Rise of Open-Source 3D Printed Robots In 2020, researchers at Intel Labs introduced the OpenBot, an open-source, 3D printed smart robot that can be built for under $50. Designed to work in tandem with a modern smartphone, OpenBot leverages the phone’s computing power to autonomously navigate and perform real-time sensing tasks—such as person-following and basic reconnaissance. By releasing the project as open source, Intel aims to empower a global community of tinkerers to push the boundaries of low-cost robotics. In a similar spirit, researchers from the NYU Tandon School of Engineering and the Max Planck Institute for Intelligent Systems (MPI-IS) developed Solo 8, a fully open-source, 3D printed quadruped robot dog. Engineered to be both low-cost and scalable, Solo 8 offers robotics enthusiasts and educators an affordable entry point into legged locomotion research. Its modular construction allows users to build and experiment with their own robotic companion without the prohibitive costs typically associated with advanced robotic platforms. 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. Feature image shows SO-ARM101 Robotic Arm. Photo via: Hugging Face.

At the 2025 INTERNI ‘Cre-Action’ exhibition held at the Università degli Studi di Milano, London architecture firm Zaha Hadid Architects (ZHA) and Dutch 3D concrete printing specialist Vertico presented Aevum, a collaborative installation that explores the intersection of historical stone carving and robotic concrete 3D printing. Aevum, meaning “eternity” in Latin, consists of two offset arches measuring 6 by 6 meters. One arch is carved from solid marble; the other was produced using Vertico’s large-scale 3D concrete printing system. The 3D printed arch comprises 21 unique elements, stands 5.6 meters tall, weighs 5.5 tons, and was printed over six days. Installation was completed in seven days, with structural and fabrication support provided by Carpenterie Pezzetti and Eckersley O’Callaghan. “This project is a real milestone,” said Volker Ruitinga, CEO of Vertico. “It establishes the legitimacy of 3D printed concrete by juxtaposing it with established marble craftsmanship. The speed, low cost, form freedom, and short delivery times promised by additive manufacturing are showcased here.” The Aevum structure consists of two staggered arches measuring 6 x 6 meters. Photo via Vertico. Material Development and Circular Design Focus The printed structure was fabricated using Vertico’s Accelerator printhead mounted on a robot-on-track platform. A custom Sika cement mix enabled the production of non-planar geometries and large overhangs required by ZHA’s design. The printing process prioritized design accuracy within a compressed timeline. In addition to form and technique, the installation incorporates waste-based material use. Marble dust—generated as a by-product of the stone processing industry—was used in the 3D printable concrete. This aligns with Zaha Hadid Architects’ ongoing research into circular material systems and additive manufacturing. “It is with good reason that the courtyard of the Università degli Studi di Milano is admired to this day, making it the ideal backdrop for this architectural conversation,” said Volker Ruitinga, CEO of Vertico. 3D printing of an arch structure. Photo via Vertico. How 3D Printing Is Impacting Arts and Sculptures 3D printing technology is increasingly being used to preserve and reproduce cultural heritage, from ancient artifacts and relics to new sculptures and monuments. This month, as part of London’s Natural History Museum (NHM) 150th anniversary celebrations, a new gallery has opened showcasing the ‘Fixing Our Broken Planet’ exhibition. The exhibition display cases were created in collaboration with the NHM’s in-house team and LAMÁQUINA, a Barcelona-based 3D design and manufacturing studio, using 3D printed ceramics incorporating recycled clay and biopolymer joints. The gallery was restored to preserve its Victorian features while integrating sustainable design and materials, in line with the Museum’s commitment to innovation and heritage conservation. In 2022, researchers at University College London (UCL) combined X-ray imaging, artificial intelligence, and 3D printing to recreate a lost painting by Vincent Van Gogh titled The Two Wrestlers. Working with artist Jesper Eriksson, the team used X-rays to examine paint layers beneath an existing canvas. The data was then processed using an AI algorithm trained on Van Gogh’s style, producing a 3D model that reflected the missing artwork. 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. shows Featured imagethe Aevum structure consists of two staggered arches measuring 6 x 6 meters. Photo via Vertico.

Before RAPID + TCT 2025 kicked off, Materialise celebrated its 35th anniversary at its North American headquarters in Plymouth, Michigan. During the event, which included a guided tour of the Belgian software developer’s medical 3D printing facility, I sat down with CEO Brigitte de Vet-Veithen.   We discussed the importance of building a strong presence in the U.S. amid uncertain trade policies, certification challenges in additive manufacturing, 3D printing for mass production, and her outlook for the future of 3D printing.  The Materialise CEO highlighted where 3D printing is being leveraged to produce millions of parts and touched on her company’s increasing focus on defense applications. Significantly, de Vet-Veithen called additive manufacturing a “slow revolution.” She explained how the company’s “North Star” approach influences its “longer-term perspective.”  Read more 3D printing news and executive insights from RAPID + TCT 2025 For de Vet-Veithen, collaboration is key. “Our competition is not each other in AM,” she said. “Our competition is traditional manufacturing.” These values were reflected by Materialise’s RAPID + TCT announcements, which included two new build processors developed in partnership with One Click Metal and Raplas. For the latter, Materialise’s technology has accelerated 3D printing speeds by up to 40%. In other news, Materialise introduced a new update to its Magics software that integrates nTop’s implicit geometries to reduce build preparation times from days to seconds.  While doom-laden discourse prophesying the death of additive manufacturing persists from some quarters, de Vet-Veithen is more optimistic. She believes “we’re still at the start of AM adoption,” emphasizing the significant opportunity in the medical, aerospace, and defense sectors. Materialise delivers 280,000 3D medical devices annually and has fabricated over 500,000 aerospace components.      However, de Vet-Veithen cautioned against overhyping 3D printing. Appointed CEO of Materialise in January 2024, she believes the industry has yet to reach a pivotal inflection point. While signs of progress are encouraging, she emphasized the need for patience, demonstrable results, and a focus on application-driven solutions.  Materialise CEO Brigitte de Vet-Veithen. Photo via Materialise. Materialise’s strategic presence in the United States  As I spoke with de Vet-Veithen on April 7, 2025, the economic impacts of the Trump administration’s sweeping tariffs, announced the week prior, were already unfolding. On the day of our meeting, the Dow Jones Industrial Average dropped 349 points and the S&P 500 slipped 0.23%, as tensions in the U.S.-led trade war escalated. Despite these concerning headlines, Materialise’s CEO remained pragmatic. Although the full impact remains unclear, she noted that shifting trade dynamics could drive domestic 3D printer adoption. “It will definitely impact us, and hopefully in a good way,” added de Vet-Veithen.  The HEC Liège alumna acknowledged the risk that aggressive tariff policies pose to Materialise’s supply chains. However, she emphasised the strategic advantage of maintaining a U.S.-based manufacturing facility. “It’s hugely important for us to have a presence here because the US is a hugely important market in the additive industry,” she said. The CEO singled out the medical sector as a critical segment within America’s borders. Materialise manufactures around 280,000 3D printed implants and medical instruments annually, including 160,000 for the U.S. market. In 2023, the Leuven-based company expanded its Michigan base with a new metal 3D printing hub. This state-of-the-art facility features multiple laser powder bed fusion (LPBF) systems dedicated to patient-specific devices like titanium cranio-maxillofacial (CMF) implants used in facial reconstruction surgery. Before opening the facility in 2023, Materialise had manufactured CMF devices at its AM facility in Belgium. Now, the company can respond more quickly to the needs of surgeons in hospitals across the U.S., reducing lead times for patients requiring personalized implants.“Everything we do is patient-specific,” added de Vet-Veithen. Materialise’s Plymouth site handles the full workflow, from converting medical images into design files to 3D printing, post-processing, and quality assurance in a 10,147 Square foot clean room.  Materialise also runs a polymer (resin and SLS) 3D printing operation at its U.S. headquarters, prioritizing anatomical models, surgical guides, and personalized implants. Elsewhere in the building, the Belgian company conducts R&D, software development, automotive tooling, and 3D printed insole commercialization.     Materialise’s U.S. Headquarters in Plymouth, Michigan. Photo by 3D Printing Industry. Overcoming 3D printing certification challenges    Although 3D printing holds major potential for demanding applications, stringent certification requirements remain a significant barrier to adoption. This is also a critical challenge for other regulated industries like aerospace, space, defense, and automotive.  However, de Vet-Veithen suggested that the last decade has seen real progress, at least in healthcare. “We’ve made huge progress in figuring out how to deal with the regulations and how to get the right certification in place,” she stated.  De Vet-Veithen stressed that Materialise does not write regulations directly. However, the company has worked openly with authorities like the U.S. Food and Drug Administration (FDA) to create awareness around additive manufacturing technologies. “We have always been very open to working with the FDA, to help them understand what additive manufacturing is,” she said. The goal for de Vet-Veithen is to increase certainty around clear regulatory frameworks to help foster future adoption, accelerate innovation, and boost investor confidence.  Materialise also actively collaborates with standards organizations alongside its regulatory efforts. De Vet-Veithen praised these groups, calling their work in additive manufacturing “amazing.” Organizations like the International Organization for Standardization (ISO) and ASTM International depend on industry experts and “members like us” to shape frameworks to encourage wider 3D printing adoption. “As an industry leader, we must take on that role and responsibility,” she said.  De Vet-Veithen believes the aerospace and defense industries are earlier in the certification journey than the medical sector. “There’s still more work to be done on that side, but we can learn a tremendous amount from what we’ve done in medical,” she explained. As with healthcare, Materialise is engaging closely with other sectors to help foster understanding around 3D printing and support the creation of new regulations.  Materialise has established a robust portfolio of flight-ready accreditations, including EASA Production Organisation Approval and EN 9100 certification for manufacturing flying parts. These credentials have enabled the company to deliver more than 500,000 3D-printed components to the aerospace sector. It currently produces around 4,000 distinct part types each year. Materialise supports the full aerospace and aviation value chain, serving OEMs, airlines, MROs, and suppliers. In early 2025, it expanded this presence by opening an Aerospace Competence Center at the Aerospace Innovation Hub in Delft, the Netherlands. Following the release of its first-quarter 2025 results last week, de Vet-Veithen told investors the company is reassessing its role in the defense sector by extending “our offering into this segment.” The shift comes amid what she called a “breakdown of traditional global alliances,” as geopolitical tensions escalate. De Vet-Veithen said deeper involvement in defense 3D printing would further reinforce the company’s position in aerospace and unlock “new opportunities in the future.” Transseptal puncture heart model 3D printed by Materialise. Photo by 3D Printing Industry. 3D printing for mass production De Vet-Veithen believes the industry is at a “critical point.” She argued that “we really need to push the boundaries on getting serial manufacturing going.” Materialise’s CEO added that the company’s software can play a “tremendous role” in allowing companies to scale their operations into serial production. The value of Materialise software is not just in automation, but in building intelligence into the production chain. Capturing and leveraging data from across workflows to monitor builds and inform future projects is critical, de Vet-Veithen emphasized.  But what scale is possible with additive manufacturing? Had I asked this question a few years ago, de Vet-Veithen would have told me not to look at high-volume applications. However, she explained that this “reality is changing as we speak,” amid growing technological maturity, application development, and automation. She pointed to China, where 3D printing is not just manufacturing thousands of parts. Instead, “we’re talking millions of parts,” especially for electronics applications. De Vet-Veithen also highlighted impressive volumes in the healthcare sector. She pointed to “millions of implants” produced with additive’s functional benefits, such as complex porous structures.  Even so, de Vet-Veithen cautioned that mass manufacturing is not the most suitable entry point for those adopting 3D printing. “Is it the best way for people to start? No, absolutely not,” she said. Instead, additive manufacturing is most valuable where it delivers clear design or functional advantages, rather than as a like-for-like substitute for conventional production methods. That said, she believes the industry is steadily uncovering “more and more applications where the functional benefits really are there.” Neurovascular Procedural Plan model 3D printed by Materialise. Photo by 3D Printing Industry. Materialise’s outlook on the future of 3D printing Forecasting trends in AM is complex, de Vet-Veithen acknowledged, because leading and lagging indicators differ sharply by application area. In healthcare, for example, improved reimbursement pathways for patient-specific solutions could dramatically accelerate adoption. However, such mechanisms are irrelevant to other sectors like aerospace or defense. Despite these nuances, she outlined a five-year vision for Materialise and the broader 3D printing industry. Central to this outlook is the increasing adoption of AM for serial manufacturing. “I absolutely believe that it’s going to happen,” she stated, pointing to the potential for workflow efficiencies and lower cost per-part amid increasing technological maturity.  Additionally, de Vet-Veithen expects the defense, aerospace, and healthcare sectors to be key drivers of 3D printer adoption in the coming years. She clarified that this does not yet represent an inflection point for AM. However, this reality will move closer as the decade nears its end, according to de Vet-Veithen.  She also explained that artificial intelligence (AI) and data-driven manufacturing will begin to transform workflow management. “We shouldn’t overhype AI, but there is potential,” she cautioned. “You can only do smart manufacturing leveraging AI if you have the data.” This is where Materialise’s CO-AM platform comes in. The company is “pushing the boundaries” with its software to help users collect data that can be used to build AI models.    De Vet-Veithen concluded that while additive manufacturing represents a transformative shift, its full impact will take time to materialise. “There’s hard work needed to make it happen, and there are a lot of steps that need to be taken.” She urged industry peers to adopt a long-term perspective rather than focus on short-term gains, arguing that only a collective, sustained effort will deliver the impact “we all dream of.” Read all the 3D printing news from RAPID + TCT 2025 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 Materialise’s U.S. Headquarters in Plymouth, Michigan. Photo by 3D Printing Industry.

The 3D printing events schedule is increasingly busy, seemingly with an additive manufacturing forum or function taking place practically every week. Here we highlight several upcoming summits, symposia, and showcase highlights for your diary. Already in 2025, the 3D Printing Industry team has reported from leading events like the AMUG Conference and RAPID + TCT. Our reporters have also attended smaller, more focused events – disseminating useful insights, increasing visibility, and providing a depth of coverage that aligns with our knowledge sharing objectives. Also, keep an eye out for our upcoming reports from AM Platform and AMUK events and the Materialise 3D Planning and Printing in Hospitals Forum. 3D Printing in the Tyre Mold Industry – 8th May 2025 The tyre mold industry is facing significant challenges due to the increasing complexity of tyre tread designs and the high precision required to produce them. Traditional manufacturing methods are struggling to keep up. In this live webinar in partnership with UnionTech, we dive into how Additive Manufacturing can help cut lead times, reduce costs, and achieve unrivalled accuracy for the tyre mold patterns of tomorrow. Join us on Thursday May 8th | 9:00 BST | 10:00 CET | 16:00 CST along with guest speaker Stanley Leung, Senior Director of Sales at UnionTech. Register for the live webinar here. Patterns on Wheels: 3D Printing in the Tyre Mold Industry. 3D PRINT Lyon – 3rd to 5th June 2025 As the premier professional event for additive manufacturing in France, 3D PRINT Lyon stands as a key hub for innovation, knowledge sharing, and industry exchange. The event offers a complete overview of the latest technological breakthroughs in 3D printing. Meet professionals spanning the entire additive manufacturing value chain, ready to deliver real-world solutions tailored to your industrial needs.  In addition to the expo, the speaking program features representatives from Airbus Helicopters, Ariane Group, Stratasys and HP. 3D Printing Industry will join a panel moderated by Tuan Tranpham and featuring Terry Wohlers from Cecile Laverriere of EOS to discuss the latest global trends in AM. Free passes to 3D PRINT Lyon are available here. 3D PRINT Lyon 2025. TCT 3Sixty – 4th & 5th June 2025 TCT 3Sixty offers a comprehensive showcase of over 150 cutting-edge additive manufacturing and 3D printing solution providers. Through hands-on exhibits and live demonstrations, attendees can explore the latest technologies and discover real-world applications across multiple industries. Designed to inform and inspire, the event delivers expert-led content focused on practical implementation, helping businesses at every stage of their AM journey make informed decisions. Whether you’re new to 3D printing or looking to scale up, TCT 3Sixty is your gateway to the full spectrum of AM innovation. The 3DPI team will make the annual journey to Birmingham’s NEC, get in touch if you’d like to meet. European Healthcare Forum for Additive Manufacturing – 26th & 27th June 2025 The European Healthcare Forum for Additive Manufacturing is a focused gathering of experts driving the integration of 3D printing technologies across the healthcare landscape. From bioprinting and medical devices to 3D printing in hospitals, the forum highlights practical applications that are reshaping patient care, improving outcomes, and enabling personalized treatment solutions. Uniting researchers, clinicians, industry leaders, and policymakers, the event offers a platform for collaboration and knowledge exchange on regulatory frameworks, patient involvement, and real-world implementation. Taking place in Basel, Switzerland, EHFAM will explore how additive manufacturing can advance healthcare across Europe through cutting-edge research, practical deployment, and strategic policy alignment. 3D Printing Industry will be speaking at EHFAM 2025, registration is open now. Stefanie Brickwede and Florian Thieringer at EHFAM 2024. Photo via EHFAM. Formnext Asia Shenzhen – 26th to 28th August 2025 Building on the Formnext model from Frankfurt, Formnext Asia Shenzhen brings together the full additive manufacturing value chain from design and pre-processing to post-production and finishing. The event showcases cutting-edge AM equipment, materials, post-processing technologies, inspection systems, and integrated solutions, offering a comprehensive view of the industry’s capabilities. The 2025 edition marks a significant expansion, incorporating a broader spectrum of advanced manufacturing technologies, including digital production, automation, and precision forming. By aligning additive manufacturing with wider industrial solutions, Formnext Asia Shenzhen fosters innovation across the entire production workflow—accelerating the transformation of China’s manufacturing landscape. Returning to Formnext Asia Shenzhen, 3D Printing Industry will report from event. More information is available here. Shenzhen World Exhibition and Convention Center. Photo by Michael Petch. AM Ceramics – 21st & 22nd October 2025 At AM Ceramics 2025 in Vienna, the world’s foremost experts in ceramic 3D printing will gather once again to share cutting-edge developments and fresh perspectives. From contract manufacturers and pioneering researchers to major industry innovators, this event offers a unique opportunity to connect with the leading minds shaping the future of ceramics. Discover the latest advancements in serial production and industrial applications, and explore groundbreaking achievements in medical and dental 3D printed ceramics. Speakers include representatives from CERN, ASTM, Lithoz, and 3D Printing Industry. More information and tickets are available here. Additive Manufacturing Strategies 2026 – 24th to 26th February 2026 Looking further ahead, Additive Manufacturing Strategies (AMS) returns to New York. AMS is an in-person business conference that unites global stakeholders across the AM ecosystem, from startups and investors to industry leaders and innovators.  Speakers from Materialise, Cantor Fitzgerald, AM Ventures, and 3D Printing Industry will join the three days of high-impact panels, keynotes, and focused discussions on the most pressing issues shaping the future of AM. With a curated, face-to-face format, AMS provides unparalleled opportunities for networking, deal-making, and strategic insight. Register for Additive Manufacturing Strategies here. Upcoming 3D Printing Events Organising an event? Add it to the 3D Printing Industry Event Guide now. Contact us for more details if you’d like 3DPI to speak at, report from, or promote your upcoming additive event. What 3D Printing Trends are shaping the industry? 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 Formnext Shenzhen. Photo by Michael Petch. Michael Petch Michael 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.

The Additive Manufacturing Users Group (AMUG) has announced the winners of its 2025 Technical Competition, recognizing outstanding work in additive manufacturing applications and finishing techniques. Selected by a panel of industry experts, entries from NASA’s Jet Propulsion Laboratory (JPL) and Equispheres won in the Advanced Finishing and Advanced Concepts categories, respectively, while Ricoh 3D for Healthcare secured the Members’ Choice Award. The competition was held during the annual AMUG Conference, March 30–April 3, 2025, in Chicago, Illinois. The panel of judges consisted of ten AMUG DINOs: Rey Chu, Director at PADT; Joerg Griessbach, Owner of Der SL PROFI; Tom Mueller, President of Mueller Additive Manufacturing Solutions; Bruce Okkema, President and Owner of Eagle Design & Technology; Rick Pressley, Director of Programs at Renaissance Services; Elton Rooney, Technical Developer at EMI Corp; Harold Sears, Head of Advanced Manufacturing at IperionX; Ed Tackett, Additive Manufacturing Lead Technologist at Würth Additive Group; Sean Wise, Owner of RePliForm; and Mark Wynn, Senior Technical Specialist at Yazaki North America. 2025 Technical Competition winners: Ryan Watkins, Rob Acton, Steve Geddes and Luke Hileman. Photo via AMUG. 2025 Technical Winners In the Advanced Finishing category, Ryan Watkins, Research Engineer, NASA Jet Propulsion Laboratory, was recognized for his project “Mars Sample Return Crush Lattices.” The project addressed additive manufacturing limitations that initially produced lattice structures with suboptimal mass and ligament thickness. By partnering with REM Surface Engineering, JPL used a chemical polishing process to reduce the components’ mass by over 80% while meeting stringent mission requirements. The judges praised Watkins’ work, noting, “Ryan’s use of finishing to modify the force required to crush the structure is ingenious, allowing him to create a finished structure that could not be printed. He is not just modifying the appearance of the part; he is also modifying the physical properties to meet the application’s needs. This is very impressive.” Evan Butler-Jones, Vice president of product & Strategy, Equispheres, submitted the winning entry for Advanced Concepts, a project developed in collaboration with Martinrea International’s Sr Specialist Technical Steve Geddes. Titled “Applying Additive Manufacturing for Integrated Passive Cooling in an e-Motor Housing,” the project designed and produced an aluminum part using additive manufacturing that integrates a vapor chamber for two-phase passive and liquid cooling within a single structure. The part was created using laser powder bed fusion with both partial and full melting, enabling a design that cannot be achieved through conventional manufacturing. The integrated approach removes the need for additional cooling components and improves heat transfer efficiency. “Excellent in many aspects. More than 100% improvement in both energy use and heat control! The result is an additive manufacturing replacement for an existing component, forgoing the need for motor redesign. This could not have been done any other way,” said the judges. Luke Hileman, Lead technician, Ricoh 3D for Healthcare, won the Members’ Choice Award with the “Neonatal Thoracentesis Trainer.” This high-fidelity simulation model, created with advanced additive manufacturing techniques, offers realistic haptic feedback to help healthcare providers practice a delicate and critical procedure for draining fluid from the pleural space of infants. Judges described it as “a wonderful use of additive manufacturing to address life-saving medical treatment for infants.” Additional placements included Aaron Sherman, Mechanical Engineer of HellermanTyton, who took second in Advanced Finishing for “Miniature Tabletop Gaming Models by Pocket Dimension Studios,” and Brent Griffith, Product Engineer of Labconco Corporation, who finished third with “Nature’s Grip Recreated: Advanced 3D Print Finishing Techniques on Rock Climbing.” In the Advanced Concepts category, second place went to Hileman with Jacob Kallivayakik from Corporate Research and Technology of Eaton Corporation taking third for “AM for Electric Machines.” The winners, or their representatives, will receive complimentary admission to the 2026 AMUG Conference, where they will present detailed insights into their projects and processes. The AMUG DINO award. Photo via AMUG. DINO Award Winners Recognized for Their Industry Contributions Among the 2025 honorees was Amy Alexander, Unit Head and Mechanical Development & Applied Computational Engineering at Mayo Clinic, who was commended for her dedication to mentoring early-career professionals. Dan Braley, Senior Technical Fellow at Boeing Global Services, was also recognized for his sustained involvement in industry events—particularly the AMUG Conference—and his ongoing efforts to advance additive manufacturing. In 2024, AMUG honored other five distinguished individuals with DINO Awards for their industry contributions: Jamie Cone, Steve Grundahl, Thomas Murphy, Vadim Pikhovich, and Bob Renella. Gary Rabinovitz from Reebok was also presented with the coveted Lifetime Achievement Award, making it only the second time in AMUG’s 36-year history that this award has been bestowed. 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 2025 Technical Competition winners: Ryan Watkins, Rob Acton, Steve Geddes and Luke Hileman. Photo via AMUG.

Ukrainian-German startup LEMKI Robotix, in collaboration with German large-format 3D printing specialist iScale3D, has introduced the DISCOVER 3D, which they describe as the world’s first 3D printed mobile home. Manufactured using Fused Granulate Fabrication (FGF) technology, the mobile home is made from a composite material of recycled polypropylene, equivalent to around 7,400 plastic bottles, combined with fiberglass for added strength. The use of these sustainable materials helps reduce both production time and costs, presenting a new opportunity for mass production of eco-friendly housing solutions. 3D printed caravan Discover 3D. Photo Iscale 3D. Lightweight and Durable Construction The DISCOVER 3D camper is manufactured using KUKA robotic systems and proprietary software, ensuring precision in the production of large-scale components. The 3D printing process allows for a build volume of 3200 x 3200 x 8000 mm, enabling the creation of structurally robust elements. Weighing just 250 kg, the camper hull is reinforced with fiberglass and features 9 mm thick walls. Its aerodynamic design minimizes wind resistance, making towing easier, while maintaining durability and structural integrity. Furthermore, the camper is 80% recyclable, reflecting a strong commitment to sustainability. Designed for off-grid living, the DISCOVER 3D can accommodate up to three people. It is equipped with autonomous battery power, solar panel compatibility, and integrated sensors to monitor temperature, water levels, and energy usage, offering flexibility to adapt to diverse environmental conditions. The interior features a sleeping nook, kitchenette, and versatile storage solutions, all designed with thermal insulation and space efficiency in mind. Kitchenette in Discover 3D. Photo Iscale 3D. Looking ahead, LEMKI Robotix plans to scale production and advance its technology, aiming to make sustainable mobile housing solutions more widely accessible to a broader audience. Advances in 3D Printing for Sustainable Housing Development Amazon’s Climate Pledge Fund has joined forces with 14Trees to advance eco-friendly infrastructure using additive manufacturing. 14Trees, backed by founding investors Holcim and British International Investment, uses proprietary 3D printing technology to build low-carbon facilities, including homes and public buildings. This strategic investment aims to deploy sustainable 3D printed materials and processes for data centers and utilities, contributing to Amazon’s larger goal of developing low-emission infrastructure.  Elsewhere, VeroTouch, a construction technology company specializing in automated 3D printing for housing, has completed Colorado’s first 3D printed homes. The firm secured up to $618,000 in funding from the state’s Innovative Housing Incentive Program (IHIP) to support further development. The funding will facilitate expansion into Cleora, where the company plans to build a 31-home development using its proprietary printing system. The two completed homes in Buena Vista, part of the VeroVistas project, are 1,100-square-foot structures designed to test the feasibility of large-scale additive-manufactured housing. VeroTouch utilized a custom-developed 3D concrete printing process to fabricate structural walls on-site, integrating automation to reduce manual labor and optimize material 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 shows 3D printed caravan Discover 3D. Photo Iscale 3D. Paloma Duran Paloma Duran holds a BA in International Relations and an MA in Journalism. Specializing in writing, podcasting, and content and event creation, she works across politics, energy, mining, and technology. With a passion for global trends, Paloma is particularly interested in the impact of technology like 3D printing on shaping our future.

Firehawk Aerospace, a manufacturer of advanced energetic systems for defense applications, announced it has been awarded a US$1.25 million Phase II Small Business Innovation Research (SBIR) contract by AFWERX, the innovation arm of the Department of the Air Force, supported by the Air Force Research Laboratory (AFRL). The funding will advance Firehawk’s work on next-generation shelf-stable propellant technologies to support national defense initiatives. “Our team looks forward to further demonstrating the performance, scalability, and affordability of our propellant solutions for air-to-air weapon systems,” said Mike Stark, President of Firehawk Aerospace. AFWERX, through programs like SBIR, supports emerging technologies that address critical operational needs, connecting small businesses to defense priorities and contributing to a more resilient industrial base. Michael Stark, Firehawk President and George Liddell, Director of Operations. Photo via Firehawk. Firehawk’s Technological Developments Under the Phase II contract, Firehawk conducts a comprehensive study of its additive manufacturing approach to solid propellants. The project scope includes formulation development, subscale motor validation, full-scale static-fire demonstrations, lifecycle cost analyses, and performance assessments. By combining advanced manufacturing techniques with production methods, Firehawk is working to modernize solid rocket motor design and production. The company’s goals include improving shelf life, facilitating efficient storage and deployment, and enabling rapid activation in contested or remote environments, helping to ensure a resilient, domestically sourced supply chain for critical energetic materials. 3D printing rocket fuel rods. Photo via Firehawk Aerospace. Recent AFWERX Awards Supporting Defense Innovation In November 2024, AFWERX awarded Kansas City-based startup Raven Space Systems a US$1.8 million Phase II Small Business Technology Transfer (STTR) contract to develop 3D printed reentry aeroshells for hypersonic flight testing. Raven Space Systems is collaborating with SpaceWorks Enterprises and the University of Illinois Urbana-Champaign’s Center for Hypersonics and Entry System Studies (CHESS) on the project. Similarly, AscendArc secured a US$1.8 million Phase II STTR contract to advance its Rapid, Scalable Geosynchronous Bandwidth technology. In partnership with Portland State University, AscendArc aims to enhance secure, resilient military communications to address critical U.S. Department of Defense operational needs. 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 Michael Stark, Firehawk President and George Liddell, Director of Operations. Photo via Firehawk.

American aerospace manufacturer Pratt & Whitney (P&W) has introduced a newly developed AM repair process designed to speed up the servicing of GTF engine components.  The aerospace manufacturer expects the new method, which it says can cut process time by more than 60%, to be rolled out across its global maintenance, repair, and overhaul (MRO) network after industrialization efforts are complete. Over the next five years, the company estimates that incorporating additive repairs into its MRO operations could help recover around $100 million worth of parts. “A more agile, additive repair process allows us to better serve our customers by improving turnaround time, while reducing tooling costs, complexity and set up,” said Kevin Kirkpatrick, Vice President of Aftermarket Operations at P&W. “At the same time, it reduces our dependency on current material supply constraints.” Pratt & Whitney has developed a new solution that will enable repair to GTF structural case features using a 3D printing method known as Directed Energy Deposition (DED). Photo via Pratt & Whitney. Repair process enhances engine overhaul Created at the company’s North American Technology Accelerator in Jupiter, Florida, the repair process focuses on restoring structural case features of GTF engines.  Rather than relying on conventional techniques, the new approach uses DED to ensure deposits of material exactly where it is needed. P&W said the process eliminates several steps from the traditional method, with most of the time savings coming from fewer machine changeovers and a reduction in heat treat cycles. Work on the solution was carried out in alliance with the Connecticut Center for Advanced Technology (CCAT) and the RTX Research Center. While the immediate focus is on structural repairs, the company plans to extend the application of the technology to refurbish components that wear down during normal engine use. The repair development is part of a broader strategy by P&W to bring advanced technologies into its aftermarket services. Earlier this year, the company announced an expansion of its technology accelerator programs to target areas such as digital inspection, adaptive processing, and advanced coating and masking techniques for key engine parts, including blades, fans, and cases.  Together, the initiatives are expected to contribute at least $24 million in annual savings once fully deployed. Alongside its North American accelerator, it complements a similar facility the company established in Singapore in 2022. That location focuses on robotics, advanced inspection techniques, connected manufacturing systems, and digital twin applications. Both sites aim to support upgrades in maintenance capabilities across the company’s global service network. As of today, the aerospace manufacturer’s GTF MRO network includes 20 shops across four continents, supported by quick-turn sites and offered through the EngineWise portfolio to help operators extend asset life and manage long-term performance. Advancing aerospace MRO Over the years, other novel ways have been explored to improve the efficiency, precision, and sustainability of repairing and assessing aerospace components. In March 2022, it was announced that GE Aerospace (at the time GE Aviation) became the first company to gain approval for using metal AM to repair commercial jet engine components, with its Loyang facility in Singapore leading the initiative.  GE Aviation has used 3D printing to produce aircraft parts, including in Boeing’s 777x jet engine (pictured). Photo via Boeing. Having leveraged 3D printing, particularly GE’s Concept Laser M2 machines, the company halved repair turnaround times, increased daily repair capacity, and reduced floor space requirements by one-third. Initially applied to high-pressure compressor blade repairs, the automated process uses image analysis to customize each part. The approach also supports sustainability goals by reducing waste, energy consumption, and the need for part replacements. On the software front, Nanyang Technological University Singapore (NTU Singapore) researchers developed a rapid, low-cost imaging method to assess the microstructure and material quality of 3D printed metal parts.  Using an optical camera, flashlight, and proprietary machine-learning software, the system analyzed surface crystal patterns within 15 minutes at a fraction of the cost of electron microscopy. The method aimed to benefit industries like aerospace by simplifying certification and quality assessment for mission-critical parts used in MRO. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows Pratt & Whitney has developed a new solution that will enable repair to GTF structural case features using Directed Energy Deposition (DED). Photo via Pratt & Whitney. Ada Shaikhnag With a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

At RAPID + TCT 2025, I spoke with Dr. Arun Jeldi to discuss his first four months at the helm of Velo3D. He outlined a revised strategic direction as the new-look company plots a path to profitability.    In January 2023, Velo3D launched a strategic review after a stretch of financial and regulatory setbacks. One year later, amid a NYSE noncompliance notice and declining revenue, the Californian company ceded 95% of its shares to Arrayed Additive. The transaction prompted a leadership change, with Jeldi, Arrayed’s chief executive, replacing Brad Kreger as Velo3D’s CEO. In the re-shuffle, Kreger was made Chief Operating Officer.    Standing in the Velo3D booth at Detroit’s Huntington Place exhibition center, Jeldi outlined his journey from healthcare to entrepreneur and 3D printing executive. An NTR University of Health Sciences graduate, Jeldi has built a substantial portfolio within the manufacturing sector. Besides Velo3D and Arrayed Additive, he leads magnesium manufacturing firm Lite Magnesium Products and magnesium extraction specialist Crown Magnesium Inc.  Since becoming Velo3D CEO, Jeldi has charted a new course for the Fremont-based metal 3D printer OEM. The company’s new Rapid Production Services (RPS) offering shifts the business beyond machine sales, aiming to provide scalable metal additive manufacturing capabilities.  Jeldi explained his goal to achieve financial stability and ensure the firm is “moving in the right direction” by addressing customer demand. According to the new CEO, his first 90 days at Velo3D have exceeded all expectations, with “a lot more demand than we expected.” He also shared insights into the value of 3D printing for defense, aerospace, and space applications and revealed plans to build a new factory in the American Midwest.      Read more RAPID + TCT 2025 news and executive insights    A part 3D printed using Velo3D’s Sapphire technology on display at RAPID + TCT 2025. Photo by 3D Printing Industry. Velo3D’s financial challenges  Jeldi’s priority in his first 90 days as CEO was to chart a “new direction” for Velo3D. Previously, the Californian firm prioritized manufacturing and selling 3D printers to generate revenue. This approach guided the development of its Sapphire range of metal laser powder bed fusion (LPBF) systems, including the Sapphire 1MZ and Sapphire XC 3D printers.  Velo3D’s products stand out thanks to their non-contact recoater technology. Most LPBF systems incorporate recoater blades that physically spread metal powder material across the build plate. This can create defects and inhibit design complexity. Velo3D’s recoated blades are suspended above the powder bed and use controlled air to spread material, reportedly unlocking more complex geometries and enhancing build quality.  Despite these advantages, Velo3D machine sales alone have struggled to sustain the company’s cash flow. The firm saw its revenue decline YoY in each quarter of 2024. FY 2024 revenue dropped 47.1% YoY from $77.4M to $41.0M. Additionally, dipping Velo3D stock prices caused the firm to receive two NYSE noncompliance notices in as many years. While Velo3D posted a -$82.3M operating loss in FY’24, this figure improved by 38.2% from -$133.3M the previous year. Adjusted EBITDA, net loss, and gross margin are also moving in the right direction.   Meanwhile, Nikon SLM Solutions, a key competitor in the market, has capitalized on growing demand. Last year, Lockheed Martin opened a 16,000-square-foot additive manufacturing facility featuring multiple SLM NXG 3D printers. Nikon’s quarterly earnings consistently cite rising interest in its large-format 3D printers, particularly from clients in the aerospace, space, and defense sectors. In FY 2024, Nikon’s Digital Manufacturing segment, which includes Nikon SLM, reported a 42.4% year-on-year revenue increase to ¥59.9 billion, driven by expanded 3D printer sales. The Sapphire XC 1MZ. Photo via Velo3D. A Strategic Pivot at Velo3D Jeldi has shifted Velo3D’s strategic approach to remain competitive, removing its reliance on 3D printer sales. He noted that the company “had a different view on the market before,” but has now transitioned with a new focus on “real strategy and financial stability.”  At the heart of this strategy is Velo3D’s newly launched RPS offering. Introduced last month, RPS gives customers access to Velo3D’s production cells, allowing them to scale manufacturing without significant capital investment. The service targets rising demand in the U.S. for flexible, scalable, and localized production, particularly from aerospace, defense, and energy customers. Jeldi also revealed that his company is actively working with 3D printing material and metal feedstock suppliers to improve vertical integration and “create an ecosystem for our customers to be successful.”   Through the RPS workflow, Velo3D collaborates with clients to develop solutions tailored to their application needs, promising shorter design cycles and faster qualification. Metrology software, 3D printing process control tools, and data-driven analysis are integrated to enhance part reliability, output predictability, and certification at Velo3D’s production hubs.           In a Velo3D press release, an unnamed “leading aerospace engine manufacturer” stated, “RPS achieved more in four months than we were able to accomplish in the previous four years.” The firm reportedly used Velo3D’s new service to produce 11 large-format proof-of-concept parts using three materials, moving two into its production pipeline. It also claims to have made “substantial progress” in qualifying IN718 material.    The Velo3D booth at RAPID + TCT 2025. Photo by 3D Printing Industry. 3D printing for aerospace, space, and defense  Demand for Velo3D’s revamped operations has surged, according to Jeldi. The company had expected a “10% or 20% increase in orders” by the third or fourth quarter. However, within the first 90 days of 20253, orders had doubled. “It’s clear that there’s a lot more demand than we expected,” Jeldi said. According to Velo3D’s new CEO, this unexpected uptick in orders has been driven by growing demand in 3D printing for defense, space, and aerospace applications. These sectors increasingly require rapid prototyping capabilities and a high-mix of complex geometries in small volumes. “Space is booming. Ammunition is booming,” explained Jeldi. This growth comes amid a challenging international geopolitical environment, with America’s security and aerospace organizations seeking more secure and localized supply chains.  For instance, under a week after our conversation, Velo3D signed a five-year, $15 million master services agreement (MSA) with U.S. commercial space company Momentus, Inc. The deal will see Jeldi’s company provide consulting and part fabrication services through its RPS offering, accelerating the production of space systems components.  Momentus plans to use these 3D printed components in its satellites, Orbital Service Vehicles, and other space systems. According to the San Jose-based firm, Velo’s LPBF technology will unlock more optimized designs, lower production costs, enhance part reliability, accelerate prototyping, and open new revenue streams     Velo3D’s new leader believes the key advantage of additive manufacturing for defense lies in its ability to accelerate the transition between concept, design, prototype, and production. He explained that traditional manufacturing is “backlogged” and hampered by slow processes and skill gaps.  While AM boosts production efficiency, Jeldi recognizes that Velo’s 3D printing capabilities are unsuitable for high-volume, million-part production runs. Instead, the company excels at delivering small numbers of high-quality, AM-optimized metal parts. This is a key reason behind Velo3D’s focus on defense and aerospace over other verticals, such as automotive. “We’re not driving in automotive in any way because we want to be in this space,” Jeldi explained.  An aerospace component 3D printed by Velo3D. Photo by 3D Printing Industry. The future of 3D printing at Velo3D For Jeldi, the future of 3D printing at Velo3D is bright. Amid strong demand for the company’s new RSP service, Jeldi revealed plans to build a new 3D printer production facility in the American Midwest.  This expansion will see Velo3D grow its production capabilities across the United States, shifting manufacturing closer to customers and labor pools better suited for scaled operations. While Velo3D has not yet selected a final location, Jeldi aims to have the new facility in full production by 2027 or 2028. Additionally, the company is set to retain a presence in California. R&D operations will remain in the Golden State due to a “lack of skill set in the Midwest.”  Velo3D’s new CEO isn’t just planning for the next three years, he’s looking 25 years ahead. Jeldi’s long-term roadmap includes developing a next-generation Velo3D printer. He explained that the company’s R&D efforts focus on creating a fully automated machine that any OEM can operate with minimal experience. At the same time, Velo3D plans to improve cost stability and scale up production to meet growing RSP demand. In the Midwest, the company aims to expand further with multiple new facilities and to build a network of contract manufacturers, creating a secure 3D printing ecosystem. Jeldi was clear that additive manufacturing cannot solve all manufacturing challenges within the aerospace, space, and defense sectors. Instead, the future will see Velo3D increasingly leverage AM in a “hybrid model” that combines traditional manufacturing methods. The recently appointed CEO revealed that customer feedback is guiding this roadmap. Velo3D is talking directly with its customer base to deliver value, and has noted growing demand for faster production capabilities. Jeldi is confident that better aligning operations with the clients’ future vision “will make us successful.”   Read all the 3D printing news from RAPID + TCT 2025 Who won the 2024 3D Printing Industry Awards? Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows a part 3D printed using Velo3D’s Sapphire technology on display at RAPID + TCT 2025. Photo by 3D Printing Industry.

Welcome to the latest edition of our 3D printing jobs and career moves update for the additive manufacturing sector.  In this edition, we’ll highlight recent developments and movements in the industry’s workforce, shedding light on the dynamic landscape of the additive manufacturing sector. Read on for recent hires at Tekna, UltiMaker, PostProcess, and The Royal Society. New leaders shaping AM and academia Canadian plasma system and material developer Tekna (Tekna Holding AS) has brought in new leadership, naming Claude Jean as its next CEO, effective today. Jean brings more than 30 years of experience in semiconductors and digital imaging, having held senior roles at Teledyne Technologies, including Executive Vice President of Strategy & Partnership, Semiconductor, and General Manager of Teledyne DALSA.  He also holds an MSc in Physics and an MBA from the University of Sherbrooke. As Tekna welcomes Jean, the Board extended its thanks to outgoing “CEO Luc Dionne for leading Tekna through a period of strategic growth in a very dynamic era for the Additive Manufacturing industry,” said Dag Teigland, Chair of the Board of Tekna. Next up, Netherlands-based 3D printer manufacturer UltiMaker has named Andy Middleton as its new Senior Vice President–EMEA, as the company looks to expand its reach and sharpen its global marketing efforts.  With nearly 20 years of experience in the 3D printing industry, Middleton is set to play a key role in boosting customer adoption and driving strategic growth across the EMEA region. He joins UltiMaker with a strong track record from companies like Hewlett Packard (HP), Stratasys, and XJet, where he guided teams operating in both mature and developing markets. Senior VP, EMEA, Andy Middleton. Photo via UltiMaker. “I’m excited to join UltiMaker at such an important time,” said Middleton. “The launch of the UltiMaker S8 is a crucial step forward, and I’m looking forward to contributing to the team’s efforts to expand the company’s offerings. With more exciting times ahead, I’m eager to help lead UltiMaker through the next phase of growth and support its mission to deliver impactful 3D printing solutions to customers.” The Royal Society in the UK has selected Dr. Martin McMahon as one of its Entrepreneurs in Residence. Through this initiative, Dr. McMahon will work with Anglia Ruskin University (ARU) to lead the Additive Anglia project, aimed at integrating 3D printing technologies into the university curriculum and creating a regional hub for additive manufacturing.  A trained metallurgist and independent consultant, he brings extensive experience in improving part quality, accelerating build rates, and reducing scrap. Since its School of Engineering and the Built Environment houses the only metal 3D printing system in East Anglia, ARU will play an important role in expanding access to 3D printing technologies for both academic and industry partners across the region. Mark Tree, Head of the School of Engineering and the Built Environment at ARU said, “I am delighted to welcome Martin to the University and am excited about how we can apply additive manufacturing across so many different disciplines. Crucially, ARU’s engineering students will also be graduating with the latest knowledge and skills needed by industry, meaning they continue to be employment-ready.” Lastly, PostProcess Technologies has welcomed Jonathon Casey to its Board of Directors (BoD) as the company moves forward with its global expansion plans. Currently serving as Executive Vice President, Chief Integration Officer, and Chief Supply Chain Officer at Nissha Medical Technologies, Casey brings more than 15 years of leadership experience across the medical device, technology, and laboratory sectors.  Throughout his time at Nissha, he has played an integral role in driving strategic growth through organic initiatives, partnerships, and acquisitions. His expertise spans sales, marketing, and operations, with a focus on integrating acquisitions and developing scalable infrastructure. On the education front, Casey holds a B.A. in International Business and Pre-Law from Canisius University and an MBA from Boston College. Jonathon Casey, newly appointed to the BoD. Photo via PostProcess Technologies. Casey added, “PostProcess is solving critical challenges in additive manufacturing with a thoughtful, technology-first approach. I’m honored to join the Board and look forward to supporting the team as they continue to accelerate innovation in the space.” What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows 3D Printing Industry Jobs Board. Image via 3D Printing Industry.

KAV Helmets, a U.S.-based company specializing in custom-fit, 3D printed bicycle helmets, has unveiled the Rhoan, an aerodynamic road helmet designed to deliver optimal performance without sacrificing ventilation, comfort, or protection.. The helmet aims to eliminate the traditional compromises between speed and heat management that cyclists often face. Custom fit meets advanced comfort Continuing its mission to personalize protection, KAV utilizes 3D printing and powder bed fusion technology to create helmets tailored precisely to each rider’s head shape. The Rhoan introduces a removable, 3D printed retention system that allows micro-adjustments for headwear changes, ensuring consistent fit and comfort across riding conditions. At the core of the helmet’s comfort is KAV’s Air Fit Suspension System, a network of thin, 3D printed webbing that evenly distributes pressure while maximizing airflow. This structure addresses common ventilation challenges, especially for riders with thicker hair, by maintaining clear internal air channels.Aerodynamics without compromise Traditional aero helmets often reduce airflow to gain drag advantages, raising core body temperature and diminishing performance. Research shows that every 1°C increase in core temperature may reduce performance by up to 1.5%. KAV’s Rhoan counters this issue by blending aerodynamic efficiency with thermal control.The helmet matches the drag coefficients (CDA) of leading models, within 0.001, equivalent to about 1 watt at 40 km/h, while surpassing them in ventilation and cooling. Key to this is KAV’s PolyCarbon Composite, a proprietary material that dissipates heat 8x more effectively and cools twice as fast as traditional EPS foam. Paired with the Hex Honeycomb Structure 2, this internal scaffold enhances impact absorption and channels heat away from the rider’s head. KAV Rhoan´s Air Fit Suspension System. Image via KAV Helmets. Availability and custom fit The Rhoan is available directly from KAV Helmets’ website and can be customized using the company’s iPhone scanning app or a traditional fit kit. Each helmet is 3D printed in the U.S. and ships within approximately two weeks. The helmet is priced at $300, includes a five year warranty, and comes with a free crash replacement policy. KAV Rhoan 3D printed aero cycling helmet bottom view. Image via KAV Helmets. How 3D printing is redefining sports helmets and athlete’s performance The launch of the Rhoan exemplifies the growing role of additive manufacturing in performance gear.  KAV’s earlier Portola helmet, developed in partnership with Jabil Inc., used a carbon-fiber nylon composite to offer custom fit and elevated safety standards. This reflects a broader shift toward athlete-specific equipment, made possible by 3D printing. Similarly, Bauer Hockey has partnered with EOS to produce personalized 3D printed helmet inserts for ice hockey players. By employing EOS’s Digital Foam technology and Selective Laser Sintering (SLS), Bauer can create lightweight, breathable helmet liners customized to each player’s head shape, enhancing both safety and comfort. In elite cycling, Renishaw’s metal 3D printing technology supported Team GB at the 2024 Olympics, manufacturing over 1,000 parts for aerodynamic bikes that helped earn eight track medals. These advancements underscore a significant shift in sports equipment manufacturing, where 3D printing facilitates rapid prototyping, customization, and performance optimization. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? 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 KAV Rhoan 3D printed aero cycling helmet. Image via KAV Helmets.

Italian cycling components brand Prologo has released a new version of its Scratch M5 PAS saddle, keeping the shape already trusted by professionals such as Jonas Vingegaard, Egan Bernal, Sepp Kuss, and Romain Bardet.  While the geometry remains unchanged, the main update lies in the saddle’s 3D printed cover, developed to improve comfort and pressure distribution without altering fit.  Named Scratch M5 PAS 3DMSS, the new model maintains its compact 250 x 140 mm profile and continues to use an injected long-fibre carbon base. This material is a standard across Prologo’s performance line, valued for its balance of low weight, rigidity, and compliance. The Scratch M5 PAS 3DMSS saddle. Photo via Prologo. Manufacturing approach for Scratch M5 PAS 3DMSS For this version, the Italian brand has used 3D printing to produce the upper surface. According to BikeRumor, Prologo’s Multi Sector System (MSS) was combined with digital light projection, oxygen-permeable optics, and engineering-grade resins. Doing so enabled precise structural variation across the saddle surface, although the 3D printer brand has not been disclosed. According to CyclingWeekly, the 3D printed surface follows the MSS layout, dividing the saddle into three main zones: front, center, and rear. Each zone is constructed from two layers with varying geometries and densities to better support different areas of the rider’s body.  The rear is shaped to stabilize the sit bones during power efforts. The center aims to relieve pressure on softer tissues. Toward the front, the structure supports riders who shift forward during climbs or sprints. Development of the layout was informed by pressure mapping through Prologo’s MyOwn fitting system. Data collected from both professional and amateur cyclists helped shape how each zone of the saddle responds during different phases of pedaling. A central channel, known as the Perineal Area System (PAS), remains part of the design. It is intended to reduce numbness by relieving pressure through the center and improving blood flow over longer rides. The Italian company has made two rail options available. Weighing 176 g, the lighter version features Nack rails made from carbon fiber reinforced with Kevlar and aluminum filaments. The second version, using light alloy Tirox rails, weighs 209 g. Retail pricing is set at €390 and €290 respectively, with availability expected from May. A close up look at the 3D printed saddle. Photo via Prologo. 3D printing comfortable cycle saddles Whether a beginner or a professional, every cyclist knows the importance of having a comfortable saddle. And with 3D printing, this has become increasingly possible. In 2022, US-based cycling equipment manufacturer Fizik launched the Argo Adaptive, its novel 3D printed short-nose saddle, at the Sea Otter cycling show. Produced using Carbon’s Digital Light Synthesis (DLS) 3D printing technology, the saddle featured a tuned lattice cushioning designed to improve comfort and rider stability.  The Argo Adaptive followed the earlier Antares Adaptive model and continued Fizik’s partnership with Carbon under its ‘Concepts’ innovation initiative. Offered in 140mm and 150mm widths, the saddle was made available in two versions: the carbon-railed R1 and the steel alloy-railed R3, which at the time were priced at $299 and $259 respectively. One year before that, German design firm DQBD used Stratasys’ launched H350 3D printer, powered by Selective Absorption Fusion (SAF) technology, to produce fully personalized cycling saddles. The SAM saddle featured a semi-rigid, 3D printed PA11 spine and a thermoformed seat pad, customized using rider-specific pressure mapping data.  By adopting Stratasys’ SAF technology, DQBD reduced production costs by up to £22,000 and cut lead times from six months to ten days compared to traditional injection molding. The glue-less assembly also allowed for easier recycling, while offering riders enhanced comfort, support, and reduced fatigue. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows the Scratch M5 PAS 3DMSS saddle. Photo via Prologo.

A research team at the University of Houston has developed a new method for fabricating flexible, damage-resistant ceramic structures by integrating origami-inspired geometries with a biocompatible elastomeric coating. The approach leverages 3D printing to produce complex Miura-ori ceramic architectures, which are then coated with polydimethylsiloxane (PDMS), a hyperelastic silicone polymer. The result is a class of brittle materials that exhibit significant improvements in energy absorption and failure tolerance. The project was led by Maksud Rahman, assistant professor in the Department of Mechanical and Aerospace Engineering, with key contributions from postdoctoral fellow Md Shajedul Hoque Thakur. Their findings were published in the journal Advanced Composites and Hybrid Materials, providing a comprehensive account of the experimental procedures, material modeling, and mechanical testing of the ceramic origami structures. University of Houston’s engineering team designed and fabricated Miura-ori ceramic structures using slurry-based stereolithography, a 3D printing process that utilizes a silica-filled resin and ultraviolet light to build complex, high-resolution forms. The intricate origami patterns were chosen for their unique mechanical advantages, including multistability, tunable stiffness, and auxetic behavior. After printing, the components underwent a series of cleaning and drying steps, followed by multi-stage thermal sintering at temperatures up to 1271 °C. This process removed the polymer binder and fused the silica particles, resulting in a dense, load-bearing ceramic with a final density of nearly 50 percent. To ensure dimensional accuracy after sintering shrinkage, the research team adjusted the digital design files—generated using MATLAB and SolidWorks—prior to printing. Scanning electron microscopy (SEM) confirmed successful densification and grain boundary development within the finished ceramic lattice. The assembly of the origami structure and the directions for performing compression tests. Image via Springer Nature Link. The origami ceramics were coated with a thin layer of polydimethylsiloxane (PDMS), a widely used biocompatible silicone elastomer to impart flexibility. The team used a vacuum-assisted dip-coating procedure, curing the PDMS in two steps to achieve a uniform thickness of 75 to 100 microns. SEM cross-sections showed that the elastomer coating covered all surfaces and creases of the structure, while remaining superficial and not infiltrating the ceramic core. Volume analysis estimated that 91 percent of the composite consisted of ceramic, closely mirroring the structure of natural nacre, which uses brittle/soft layering to enhance toughness. Mechanical Testing Across Three Axes Compression tests were performed on both coated and uncoated origami samples in three orthogonal directions, using an Instron ElectroPuls E3000 system. Load-deflection measurements revealed that uncoated ceramics failed catastrophically at low strains, particularly along their weakest axis. In contrast, PDMS-coated samples absorbed significantly more energy before failure. The weakest loading direction showed the largest relative improvement in toughness—an effect attributed to the compartmentalized failure enabled by the elastomeric layer, which prevented cracks from propagating through the entire structure at once. SEM imaging further illustrated that the coating stopped or slowed crack growth, resulting in a stepwise, localized failure mode rather than the sudden collapse typical of ceramics. Optical images taken at various stages of compression confirmed that coated origami maintained structural integrity at strains that destroyed uncoated samples. Finite element analysis was performed using ABAQUS/Explicit, with material models tailored to both the ceramic (concrete damaged plasticity) and the hyperelastic PDMS coating (Arruda–Boyce model). Element deletion routines were employed to accurately simulate fracture and separation. Simulation results closely matched experimental findings, revealing lower stress concentrations and delayed damage accumulation in coated samples. Mesh convergence was verified, with final models containing nearly 300,000 elements to ensure numerical stability. Fabrication of the 3D-printed ceramic Miura-ori structure, followed by the application of a hyperelastic coating. Image via Springer Nature Link. Analysis of von Mises stress and maximum principal strain showed that the PDMS layer redistributed loads away from vulnerable edges and vertices. The presence of the coating reduced both tensile and compressive damage variables, with the largest reduction seen in the direction most susceptible to crack initiation. Cyclic Loading Shows Durability Under Repeated Strain Researchers further evaluated the coated ceramics under cyclic loading in the X-direction, up to a compressive strain of 1.5 percent. Uncoated structures failed at or below this threshold, but PDMS-coated samples endured multiple loading cycles with only minor reductions in peak force—evidence of crack bridging and controlled damage. Simulation of cyclic loading confirmed this trend and provided additional insight into the evolution of damage over time. The team’s approach demonstrates that combining complex origami geometries with 3D printed ceramics and hyperelastic coatings can yield macroscale structures with application-specific mechanical properties. By tuning both geometry and material composition, University of Houston engineers have created a pathway toward lightweight, tough, and biocompatible materials suitable for prosthetics, implants, impact-resistant aerospace parts, and robotic systems. Future work will focus on further optimizing Miura-ori unit cell parameters using algorithmic design and simulation to maximize performance under specific loading conditions. The team anticipates that advanced optimization techniques—such as Bayesian methods or genetic algorithms—will enable the rapid identification of optimal design configurations for new engineering challenges. Results of the experimental quasi-static compression test on the architected ceramic structure. Image via Springer Nature Link. 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 showcase the assembly of the origami structure and the directions for performing compression tests. Image via Springer Nature Link. Anyer Tenorio Lara Anyer Tenorio Lara is an emerging tech journalist passionate about uncovering the latest advances in technology and innovation. With a sharp eye for detail and a talent for storytelling, Anyer has quickly made a name for himself in the tech community. Anyer's articles aim to make complex subjects accessible and engaging for a broad audience. In addition to his writing, Anyer enjoys participating in industry events and discussions, eager to learn and share knowledge in the dynamic world of technology.

Nano Dimension completed its acquisition of U.S. FDM 3D printer manufacturer Markforged Holding Corporation (NYSE: MKFG). This announcement comes weeks after the additive manufacturing electronics firm finalized a similar deal for the industrial 3D printer OEM Desktop Metal.    Nano Dimension’s deal for Markforged was first announced in September 2024. Valued at $116 million, or $5.00 per share, the transaction has been sealed following the completion of regulatory approvals and satisfaction of customary closing conditions. As part of the agreement, Markforged’s Chief Financial Officer, Assaf Zipori, has become Nano Dimension’s new CFO.   According to a Nano Dimension press release, the acquisition gives the company a “strong foothold” in metal and composite manufacturing and marks a “leap forward” in AI-optimized production.  Ofir Baharav, Nano Dimension’s CEO, called the acquisition “a major milestone” in fulfilling the company’s vision of “building a preeminent digital manufacturing leader.” He stated that Markforged’s installed base of 15,000 systems provides a “strong platform” for expanding Nano’s global reach.  “While Markforged solutions have achieved nearly 50% gross margin, we will continue to take clear, decisive steps to drive profitability and strengthen our capital position in the quarters ahead,” Baharav added.       The Markforged FX10 3D printer. Image via Markforged. Nano Dimension’s rocky road to consolidation  Markforged’s acquisition comes after a protracted period of M&A uncertainty at Nano Dimension, marked by legal disputes and leadership upheaval. The transaction was initially valued at a 71.8 per cent premium to Markforged’s volume-weighted average price as of 24 September 2024. It formed part of an acquisition-driven strategy led by then-CEO Yoav Stern, who also initiated the $179.3M agreement to acquire Desktop Metal (DM) at $5.295 per share. Delays to both acquisitions prompted Desktop Metal to sue Nano Dimension last December, alleging that its American-Israeli buyer had failed to make “reasonable best efforts” to complete the deal. A second lawsuit named Markforged as a defendant. It accused Nano Dimension of violating its agreement with Desktop Metal and breaching its contractual obligations to the Ric Fulop-led company. Nano Dimension denied the claims, describing them as “without merit” and “inconsistent with the terms of the Merger Agreement.” Amid these legal disputes, Nano experienced a significant leadership shake-up. Yoav Stern was ousted as CEO and removed from Nano Dimension’s board of directors in December 2024. The company’s remaining directors were replaced by a new slate backed by activist shareholder Murchinson Ltd. A vocal critic of Stern and his pro-M&A stance, Murchinson previously called the agreements for DM and Markforged “overpriced” and “misguided.” The Delaware Court of Chancery later ordered Nano Dimension to fulfill its acquisition of Desktop Metal, which was finalized earlier this month.  Nano Dimension 3D printed electronics. Photo by Michael Petch Markforged’s value proposition 2024 saw Markforged generate annual revenues exceeding $85M, while non-GAAP gross margins reached approximately 50%. Previous calculations based on fiscal year 2023 figures indicated that DM and Markforged would provide a combined projected revenue of $340 million.  Nano Dimension believes that integrating the Waltham, Massachusetts-based company will strengthen its position in production-line manufacturing. It describes Markforged as an industry leader in advanced manufacturing systems, materials science, cloud-based services, and AI-driven production. For Nano, the AI advantage is pivotal. The company believes Markforged’s expertise in artificial intelligence will enable it to meet growing requirements for precision and consistency. Additionally, the business combination also looks set to extend Nano Dimension’s customer base and application reach. Markforged’s 3D printers are deployed globally across aerospace, defense, automotive, consumer electronics, industrial automation, and medical technology sectors.  Ultimately, Nano is confident it can build on Markforged’s progress in rapid manufacturing, re-shoring, supply chain resilience, intellectual property security, and sustainability. By integrating Markforged, Nano Dimension is focused on expanding its position in metal and composite 3D printing on the factory floor. It also assured investors that this new initiative will support ongoing efforts to deliver shareholder value, build a robust capital base, and improve financial performance.      Markforged HQ. Photo via Businesswire 3D printing mergers and acquisitions  Nano Dimension is not the only company executing mergers and acquisitions in additive manufacturing.  Earlier this year, US-based specialty metals expert United Performance Metals (UPM) acquired Ohio-based metal 3D printing firm Fabrisonic LLC. The deal seeks to enhance UPM’s production capabilities and expand its range of solutions. Following the acquisition, Fabrisonic will become part of UPM’s specialty processing network, which includes Thin Strip in Wallingford, CT; UPM Advanced Solutions in Cincinnati, OH; and Precision Cold Saw Cutting and Grinding in Oakland, CA. Jason Riley, General Manager of Fabrisonic, noted that the new business combination “marks an important development for Fabrisonic.” He added, “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.”  In other news, Airtech Advanced Materials Group recently acquired the 3D printing filament business of Kimya, a former subsidiary of French industrial conglomerate Armor Group. Through the deal, Airtech has received technical filaments, production and development infrastructure, validation equipment, and associated intellectual property. The Huntington Beach-headquartered firm will incorporate these assets into its catalog of additive manufacturing materials.      Read all the 3D printing news from RAPID + TCT 2025 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 Markforged’s HQ. Photo via Businesswire.

Aerospace and defense now rank among the largest and most valuable sectors adopting additive manufacturing.  Ongoing international supply chain disruptions, rising geopolitical tensions, and global conflicts threaten access to critical equipment and components vital for national security. In response, defense agencies are turning to 3D printing to cut lead times, localize production, repair equipment, and restock depleted inventories. This growing focus on 3D printing for defense was evident at RAPID + TCT 2025, which co-located with the eighth edition of SME’s AeroDef Manufacturing 2025 expo. A large section of the show floor at Detroit’s Huntington Place was dedicated to key exhibitors within the military technology ecosystem. This included heat exchanger manufacturer Conflux Technology, aerospace 3D printing firm Hyphen Innovations, and US defense manufacturing accelerator LIFT.   Read more RAPID + TCT 2025 news and executive insights    AeroDef also featured a stacked conference track. Expert-led presentations and panels provided insights into the value, opportunities, and challenges facing the defense industrial base. Major General Michael Lalor of the U.S. Army highlighted 3D printing’s role in sustaining 70% of the infantry’s combat inventory. He also emphasized its importance for building an “arsenal of democracy” in Detroit.  RHH Advisory’s Tali Rosman identified 3D printing’s potential to increase the pace of American manufacturing. This is particularly significant given that China’s shipbuilding capacity is currently 350 times greater than that of the United States. A BlueForge Alliance-led panel discussed how to accelerate production in the U.S. Navy’s industrial base, highlighting the value and challenges surrounding 3D printing adoption.         Elsewhere, Dr. Bill Anderson highlighted the cybersecurity threats that malicious foreign actors pose to the digital ecosystem of additive manufacturing. Boeing’s Daniel Braley was also on the agenda. He highlighted vulnerabilities in the supply chain for critical minerals and materials, citing the “threat of the U.S. going to full-scale war in one to two years.” As geopolitical tensions rise and global supply chains constrict, all speakers broadly agreed that 3D printing will become a critical strategic pillar in safeguarding the West’s defense industrial base. The AeroDef Manufacturing 2025 expo show floor. Photo by 3D Printing Industry. Major General Michael Lalor: Advanced manufacturing at U.S. Army TACOM Major General Michael B. Lalor, Commanding General of U.S. Army Tank-automotive and Armaments Command (TACOM), opened the AeroDef conference with a welcome address. Headquartered at Detroit Arsenal, the Command manages 70% of the U.S. Army’s ground combat inventory. “If a soldier drives it, shoots it, or wears it, we sustain it,” Lalor explained.  TACOM oversees a $30 billion annual budget and manages over 3,500 weapon systems. According to the former M1A1 Tank Platoon Leader, these include everything from Abrams and Bradley tanks to eight-wheeled Stryker armored fighting vehicles and artillery systems. TACOM maintains a global presence. At any given time, about 350 personnel across 70 “flyaway teams” operate overseas, supporting supply chain operations for units in the field.              Collaboration with industry partners is vital for TACOM’s operations. He noted that technological evolution and supply chain complexities demand new levels of collaboration that transcend “international and traditional boundaries.” Lalor added that TACOM is leading the U.S. Army in advanced manufacturing. 3D printing is being leveraged to fabricate customized parts on demand, reducing reliance on lengthy lead times. TACOM’s Major General highlighted that the Command has seen “amazing results” through this adoption.  Over the past year, TACOM has developed its Battle Damage Repair and Fabrication Program (BDRF). The initiative leverages additive manufacturing to produce temporary replacement parts for damaged military vehicles. This reduces downtime and increases operational readiness, allowing critical warfighting equipment to be returned to the battlefield in less time.  Over 40,000 vehicle parts have been assessed for additive manufacturability in collaboration with the U.S. Army DEVCOM Ground Vehicle Systems Center and TACOM Integrated Logistics Support Center. From this, TACOM’s Rock Island Arsenal – Joint Manufacturing and Technology Center in Illinois has 3D printed more than 600 3D CAD models.  According to Lalor, these efforts are vital to relieving the substantial pressure on America’s few remaining foundries. The U.S. Army’s only operational foundry at Rock Island has seen its workload quadruple over the past 18 months amid a dearth of domestic castings and forgings capabilities.   Lalor revealed that Rock Hill Arsenal’s additive manufacturing technologies will be ASTM 9100 compliant by June 2025, when it will ramp up production of aerospace and aviation-certified parts. “There are gaps to close, and that arsenal is part of the solution,” he added.             Major General Michael Lalor speaking at AeroDef Manufacturing 2025. Photo by 3D Printing Industry. The value of 3D printing for defense In a separate presentation, Tali Rosman, a Business and M&A advisor at RHH Advisory and former Elem Additive CEO, shared her perspective on the defense opportunity for 3D printing.  Rosman emphasized the U.S. Department of Defense’s (DOD) growing adoption of additive manufacturing, suggesting that the Pentagon is “arguably the largest user” of additive manufacturing based on dollars spent. However, this adoption comes amid a challenging point for the Pentagon. According to Rosman, “China is outpacing the U.S. in terms of manufacturing.” Notably, she highlighted that China’s shipbuilding capacity is 350 times that of the United States.  Amid this threat, the DOD is adopting additive manufacturing “in earnest” to secure the U.S. defense supply chain. While it can take years to build conventional manufacturing plants, some 3D printing technologies can start fabricating parts in weeks. In today’s “volatile and uncertain world,” that speed makes the technology especially appealing. Rosman highlighted expeditionary manufacturing as one key application for 3D printing. She emphasized that conflict in Ukraine has “paved the way” for its remote deployment. Ukrainian soldiers are leveraging metal additive manufacturing, including cold spray 3D printers from SPEE3D, to increase equipment uptime and localize critical supply chains.  The U.S. Navy has also installed 3D printers on warships to conduct repairs and fabricate replacement parts at the point of need. Last year, SPEE3D’s XSPEE3D and Snowbird Technologies’ SAMM Tech hybrid DED manufacturing system were deployed during the Rim of the Pacific (RIMPAC) exercise in Hawaii. During the trial, Navy personnel sought to reduce the delivery time of critical parts from days to hours.  Additionally, Rosman highlighted increased DOD funding to restock its depleted missile arsenals using 3D printing. She pointed to Albuquerque-based aerospace firm X-Bow Launch Systems, which recently received an additional $9.85 million from the DOD to advance research into 3D printed solid rocket motors (SRMs). This new capital sees the company’s current DOD contract value rise to $28.67 million, while its total U.S. defense funding has exceeded $97 million.  Similarly, the Pentagon has backed Ursa Major to 3D print missile SRMs. Last December, the Colorado-based firm completed successful flight testing for the U.S. Army. Daniel Jablonsky, Ursa Major’s CEO, claimed that the company’s Lynx 3D printing technology unlocked “unprecedented timelines,” with nearly 300 SRM static test fires completed in 2024.          Looking ahead, Rosman anticipates that 3D printing will play an increasing role for many of America’s allies. European countries are expected to ramp up defense funding, following the Trump administration’s call for increased security spending among NATO members. For instance, Germany’s defense spending could grow to 3% of GDP by 2027, potentially exceeding 3.5% after that, according to Goldman Sachs research.  Rosman believes a “disproportionate” amount of Europe’s funding will be “flowing into the additive manufacturing sector” in the coming years. Indeed, the UK recently outlined plans to accelerate 3D printing for defense. The Ministry of Defense (MOD) aims to increase investment to incentivise adoption, adapt policies to remove barriers, and increasingly integrate additive manufacturing into the defense supply chain.      Snowbird Technologies’ 3D printer at RAPID + TCT 2025. Photo by 3D Printing Industry. Additive manufacturing bolsters the US Navy’s industrial base   The role of additive manufacturing in the U.S. submarine industrial base (SIB) is also growing. Leading this effort is BlueForge Alliance (BFA), a nonprofit defense integrator. Headquartered in Bryan, Texas, BFA coordinates manufacturing, recruitment, and technology integration to support the U.S. Navy’s manufacturing supply chain.  During a panel discussion, Tim Shinbara, BFA’s Chief Strategy Officer, sat down with James Hockey, Director of metal 3D printing service provider Incodema3D, and Greg Mallon, Chief Strategy Officer of engineering and manufacturing firm GSE Dynamics. Incodema3D and GSE Dynamics are among the roughly 16,000 companies working in America’s ship and submarine manufacturing sector.  Mallon identified workforce challenges as stunting the growth of America’s maritime industrial base. He noted that over the past 30 years, the U.S. has shifted from a goods-based economy to one driven by digital and service industries. The result? A shrunken manufacturing workforce, down from 3 million to just over a million workers. “That has left the defense industrial base very atrophied,” Mallon added.   Additive manufacturing firms, like Incodema3D, are no less affected. “Our biggest problem is still talent,” agreed Hockey. “We can’t hire people fast enough.” The 27-year 3D printing veteran explained that Incodema3D needs to be growing 25% every year “just to keep up with the scaling we’ve already done.” However, the company, which operates out of Freeville, New York, has only grown 30% since its founding in 2013. BluForge Alliance is working to alleviate these shortfalls through buildsubmarines.com, a website that connects workers with employers in the submarine industrial base. According to Shinbara, the recruitment tool offers a low-cost and effective solution to workforce challenges. “It’s only eight cents for someone to apply, and we found it’s about $700 per person to be hired,” he explained.   Buildsubmarines.com sign in Detroit. Photo by 3D Printing Industry. Adoption also remains a core challenge within maritime manufacturing. In particular, Hockey identified the need for customers to embrace design for additive manufacturing (DfAM) and understand where the value lies.  He highlighted a common issue with additive manufacturing: the assumption that it’s always the faster solution. Specifically, customers are increasingly requesting low-volume casting for legacy parts. Hockey explained that these applications offer little value unless the design includes novel geometries or features enabled by 3D printing.  For Mallon, the roadblocks to adoption go beyond the machinery, citing “a lack of enthusiasm to adopt that new technology.” He highlighted a “resistance to change” among experienced workers, often due to job security concerns or comfort with legacy systems. However, there is stronger enthusiasm for 3D printing among younger workers, who “embrace the technology much faster.”  Looking to the future of maritime manufacturing, Mallon believes hope lies in predictable defense programs and automation. “When you look at the Navy’s 30-year shipbuilding plan, each year it changes,” he said. “It’s hard to follow.” Mallon believes increased predictability would allow customers to follow through on programs and prioritize execution. Moreover, GSE Dynamics’ Chief Strategy Officer believes increased automation will improve efficiency and speed.  Hockey echoed this sentiment, highlighting his company’s internal push for tighter integration between additive manufacturing and CNC machining. Hockey predicted that streamlined workflows will ease staffing pressures while also elevating the overall skill level of the workforce.      Shinbara, surveying the broader context from Washington, D.C., concluded with a hopeful note. “The policy, posture, and funding are starting to align,” he said. “It’s probably one of the few times outside of World War Two” that the U.S. has seen this level of policy and financial momentum. Tim Shinbara, Greg Mallon, and James Hockey (L-R). Photo by 3D Printing Industry. Cybersecurity threats and logistical challenges  Security threats and supply chain challenges also jeopardize adoption and growth. Dr. Bill Anderson, Principal Product Manager at Mattermost, underscored major cybersecurity concerns. He pointed to the risks tied to additive manufacturing’s expanding digital footprint. Anderson opened his presentation with a stark warning: “The government is under attack from foreign adversaries.” He emphasized that government suppliers, contract manufacturers, and OEMs face significant risk. The digital security expert observed that even manufacturers far from the front lines are under threat, warning, “You’re being attacked now, you probably just don’t know it.” The University of Waterloo alumnus explained that, in wartime, the West’s adversaries may look to shut down suppliers’ systems. This could have knock-on effects, impacting the military and government’s ability to operate.         According to Anderson, about 70% of cyberattacks on the defense industrial base are committed by nation states. He pointed to China as a major threat, particularly Volt Typhoon, reportedly a Chinese state-sponsored hacker group engaged in cyberespionage. In 2023, this advanced persistent threat (APT) breached commercial and Navy networks near Guam. While the U.S. successfully thwarted the intrusion, the attack could have severed communications across the Pacific. Such a capability would carry serious strategic consequences, particularly amid escalating tensions over Taiwan.  Security threats also impact the supply of critical materials. Braley, a Technical Fellow at Boeing, described the global supply chain as a “perfect storm.” He explained that intensifying threats from Russia, North Korea, China, and Iran have “severely affected” America’s ability to procure raw materials and manufactured parts.  Tightening U.S. and international regulations constrain the flow of materials essential to America’s defense manufacturing. According to Braley, “the real issue for the aerospace industry” lies in recent amendments to the National Defense Authorization Act (NDAA), which introduce new import restrictions. Braley noted that most titanium powder used in metal 3D printing is sourced from China. Under the updated NDAA, the DOD could be barred from procuring Chinese titanium powder starting in June 2026. The legislation will also restrict imports of key steel and metal alloys, including nickel, iron, cobalt, zirconium, and their derivatives. Braley is especially concerned about magnesium, which he says has “trace elements in almost everything.” Since “the vast majority of magnesium comes from China,” he warned that the restrictions will “drastically affect just about every product we make in the US.”  Dr. Bill Anderson at AeroDef Manufacturing 2025. Photo by 3D Printing Industry. The future of 3D printing for defense  Despite these concerns, additive manufacturing is rapidly becoming a vital asset for defense applications. It offers value in strengthening supply chains, enhancing combat capabilities, reducing lead times, and replenishing depleted weapon stockpiles. The Pentagon has taken note, committing significant investment to scale domestic 3D printing capacity and cultivate a resilient network of additive manufacturing suppliers.  Rosman highlighted the growing market opportunity for 3D printing in defense, citing data from Additive Manufacturing Research (AM Research). In its 2024 report, the New York-based firm projected that DOD spending on 3D printing will exceed $1 billion in 2025, up from $800 million last year. U.S. investment is projected to rise steadily through the decade, reaching $2.6 billion by 2030. These findings align with the views shared by speakers in Detroit. As geopolitical tensions and security concerns intensify, 3D printing is poised to play a larger role in strengthening global defense capabilities. While Europe is expected to ramp up adoption in the coming years, the United States is already investing heavily to secure a leading position in the additive manufacturing landscape. While challenges persist, increased collaboration between state and industry seems set to accelerate additive manufacturing adoption within America’s defense industrial base.       DOD 3D printing spending growth projections. Image via Additive Manufacturing Research. Read all the 3D printing news from RAPID + TCT 2025.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 Major General Michael Lalor speaking at AeroDef Manufacturing 2025. Photo by 3D Printing Industry.

Additive manufacturing for functional ceramics continues to push the limits of material science and process engineering, particularly at the intersection of microelectronics, optics, and advanced packaging. At the 2025 AMUG Conference, experts from HRL Laboratories, Lithoz, and the National Institute of Standards and Technology (NIST) dissected the underlying challenges holding back broader adoption of 3D printing with ceramics. Insights into functional 3D printed ceramics Photopolymer chemistry is a balancing actOptical distortion from high-refractive fillers needs to be understood.Compensating for shrinkage and porosity to achieve small features or electrical performance is important.Debinding is an often-hidden bottleneck.Process iteration is intensive and material-specific.Vast market opportunity for those who master ceramic 3D printing  Opening the afternoon session, Russell Maier, who leads the ceramics AM programme at NIST, underscored the critical role of feedstock rheology in shaping viable ceramic parts. He warned that differences in equipment and measurement techniques can yield inconsistent rheological data, making standardisation an urgent concern for industry players. “You can measure the yield stress on one instrument and get a value that’s two to three times different than on another,” Maier said. “That’s a huge variability when it comes to deciding if a feedstock is even printable.” Yield stress is especially important for shaping electroactive ceramics, where high solids loading in slurries must be carefully controlled to ensure structural integrity post-printing. Traditionally, dense ceramics are formed via tape casting and gel casting, where binders and solvents are removed to leave packed ceramic particles. These processes are now being reimagined in additive methods, but still require deep domain expertise. “Even if you become an expert in ceramic AM, you still have to know how to fire and densify it properly. You still need to be a ceramic engineer,” Maier emphasised. He also pointed to the market opportunity for AM in multi-layer ceramic capacitors (MLCCs), which are ubiquitous in smartphones, automobiles, and industrial equipment. According to Maier, more than 1,000 MLCCs are used in a modern smartphone, and tens of thousands in a single truck. The MLCC market alone is expected to hit $16 billion this year, yet additive methods are just beginning to penetrate this space. Shawn Allan of Lithoz America provided a closer look at lithography-based ceramic manufacturing (LCM), a DLP-driven printing method that enables the high-resolution fabrication of functional ceramic parts. “We’re essentially replacing the forming step of ceramic manufacturing with 3D printing. Everything else, debinding, sintering, follows traditional processes,” Allan explained. He presented 3D printed parts made from materials such as yttria-stabilised zirconia, alumina, and transparent ceramics like yttrium aluminium garnet (YAG), which are relevant in optics and laser applications. Notably, LCM allows micron-level feature resolution and tolerances tight enough for components like surgical instruments or dielectric resonators used in 5G and satellite communications. Allan’s team has worked with federally funded research centers and manufacturers on piezoelectric ceramics, such as PZT, optimizing slurry formulations to match traditional densities and dielectric coefficients. They’ve printed Gaussian transducer arrays and negative Poisson ratio lattices for potential use in sonar, underwater communications, and directional acoustic sensors. “Eventually, we were able to manufacture a transducer based entirely on a computationally designed lattice. That kind of structure would be extremely difficult to fabricate using conventional methods,” Allan said. Functional ceramic development is now extending into multi-material printing, including co-sintered systems that combine ceramics with metals like copper or stainless steel. This raises challenges in matching thermal expansion and densification profiles during sintering. According to Allan, future success will hinge on leveraging known, industry-validated materials from traditional processes, “not developing something new, but taking advantage of what already works.” The path forward is clear: greater industry collaboration on feedstock standards and expanded use of AM for complex, functional ceramics that traditional techniques cannot match in terms of geometry or integration potential. HRL Pushes Boundaries of Curved Microelectronics with Preceramic 3D Printing and Metal Infiltration At HRL Laboratories, a cross-functional programme bridging ceramic materials and semiconductor engineering has yielded a functional, curved electronic interposer with high-resolution, high-aspect-ratio electrical vias, manufactured via additive methods. The breakthrough aims to meet the growing demand for compact, high-performance imaging systems and next-generation curved sensor arrays. Kayleigh Porter, a ceramics specialist at HRL, outlined the lab’s efforts to print complex three-dimensional via arrays with preceramic polymers, using lithography-based 3D printing and a proprietary metal infiltration process. These vias form electrical connections between curved sensor surfaces and planar readout electronics, an architecture that traditional planar microelectronics cannot address. “Standard microelectronic vias are limited to vertical or horizontal paths, and every directional change introduces signal loss,” Porter said. “With 3D printing, we can design curved or angled vias, embed passive elements, and even coolant channels directly into the part.” The team used a photosensitive preceramic polymer, a siloxane functionalised with silicon in the backbone, which forms a silicon oxycarbide matrix after pyrolysis. Unlike conventional binders that burn off, this binder becomes part of the ceramic structure, improving material stability and opening up possibilities for functional filler materials.  One of the main goals was to preserve the resolution of a 2 million-pixel curved detector. To achieve this, HRL employed a 2K DLP projection system with a two-micron pixel pitch and tailored the resin’s cure characteristics using photoinitiator blends and kinetic modelling. Maintaining image fidelity across a non-planar geometry required deactivating certain pixels to preserve uniform pitch on the curved surface, essential for optical accuracy. Filling the tiny vias, some just 10 microns in diameter, posed a metallurgical challenge. Standard electroplating techniques were unsuitable for high-aspect-ratio and curved geometries. HRL developed a copper-indium alloy with trace amounts of titanium to facilitate capillary-driven melt infiltration, achieving a 98% fill rate across a one-millimetre-thick interposer section. “For the vias to function electrically, they must be continuous from top to bottom,” Porter said. “Incomplete fill leads to dead pixels, so we validated via continuity through imaging and resistance measurements. The successful parts showed strong signal transmission across the entire stack.” Material compatibility was also a critical consideration. The coefficient of thermal expansion (CTE) needed to match that of the semiconductor substrates, typically silicon or gallium arsenide. Particle additives such as alumina and mullite were screened for shrinkage control and CTE tuning, and para-silica particles were used to minimise refractive distortion during curing. The interposer’s final metal network was polished to expose a clean metallised interface, then integrated with a thinned gallium arsenide detector chip via spike bonding and fan-out methods. A full electrical test confirmed signal integrity, validating the concept for scaled applications. While still in the prototype stage, the technology suggests a viable path to compact, high-performance imaging electronics, particularly where conformal packaging and optical curvature offer design advantages. The additive process also allows HRL to rapidly iterate sensor geometries without long lead times or retooling. “You just redesign the part and print it. That’s a huge benefit,” Porter said. Industry Pushes for Precision in Ceramic Additive Manufacturing as Resolution, Chemistry, and Debinding Remain Obstacles Russell Maier of the National Institute of Standards and Technology highlighted the material sensitivity required to access the lucrative MLCC market. “You have to be worried about trace concentrations of sodium, titanium—lightweight transition metals can ruin electrical properties,” he warned. Even residual carbon from photoresins, he said, can pose risks when sintered into a dielectric material. In photopolymer-based ceramic AM, the resin’s optical behaviour and chemical load must be tightly controlled. HRL’s Kayleigh Porter described the complex trial-and-error process of photoinitiator tuning. “We had to mix four or five different resins to really dial in what would work. It’s about pulling multiple levers at once (absorbers, initiators, reflections) and that gets tricky fast,” she explained. Reflection from high-refractive-index particles also proved problematic. Alumina, a common ceramic filler, scattered light during exposure, limiting HRL’s via resolution to 80 microns. In contrast, Porter noted, using para-silica matched to the matrix index enabled 10-micron feature fidelity. “The trade-off is less mechanical customisation, but you get the resolution,” she said. Shrinkage, another perennial issue in ceramics, was discussed across multiple speakers. Lithoz America’s Shawn Allan acknowledged the need for compensation, especially in high-resolution prints. “As features approach the pixel or layer size, you can’t rely on the STL anymore. You have to print, measure, and adjust,” he said. Allan also pointed out the challenges with partial densification: “The dielectric constant is coupled with porosity. If there’s trapped gas or incomplete sintering, the value drops.” Debinding emerged as a critical step with high stakes. “The print might take hours, but the debinding process takes a week or more,” Maier said. “It’s a black box. You go too fast, and you’ve just destroyed a week of work.” NIST typically errs on the side of caution. Gradual burnout helps preserve part geometry, especially where thick and thin sections coexist in the same structure. Porter noted that HRL’s use of active binders that convert to ceramic reduced porosity but introduced a different issue. “When we load over 25% filler, the matrix shrinks while the particles don’t. That creates internal stress, tension between particles, which can lead to cracking,” she said. HRL has previously published findings on this phenomenon, underscoring the importance of matrix-particle balance. As ceramic additive manufacturing moves closer to high-value applications, success hinges on managing micro-scale process variability and chemistry with extreme precision. Whether it’s controlling trace contaminants, compensating for shrinkage in vias, or ensuring debinding doesn’t undo a week’s worth of work, the field demands interdisciplinary expertise and deep iteration.  What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our YouTube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows a 3D printed ceramic casting core produced on the S320. Photo via Lithoz.

APWORKS, a subsidiary of Airbus focused on metal additive manufacturing solutions, and Equispheres, a Canadian producer of advanced aluminum powders, announced an alliance to establish North American production capacity for Scalmalloy. This high-strength aluminum-magnesium-scandium alloy, engineered specifically for 3D printing, will be manufactured using predominantly locally sourced raw materials. Equispheres will provide a secure North American supply chain for Scalmalloy powder, optimized for additive manufacturing. The two companies have entered a non-binding understanding and are now exploring avenues for future production, distribution, and technical alignment. Further details will be released as discussions advance. Developed and patented by APWORKS, Scalmalloy was purpose-built for laser powder bed fusion. Its mechanical properties are comparable to those of 7000 series aluminum, offering high strength, superior ductility, and excellent processability. While the alloy is licensed to producers in Europe and Asia, Equispheres is set to become the first company to establish a North American supply chain for Scalmalloy, relying on primarily regional raw materials. Scalmalloy is only available through licensed distributors, and adoption in critical aerospace, defense, and motorsport programs has been supported by a large, established database of materials data. Parts made of Scalmalloy can be welded to form larger assemblies, and its corrosion resistance is comparable to 5000 series aluminum alloys. Engineered for performance, Scalmalloy offers mechanical properties comparable to 7000 series aluminum. Photo via Equispheres. Equispheres produces optimized aluminum alloy powders that support faster build rates compared with traditional powders, achieving these improvements with no adverse effects on mechanical properties. The company’s proprietary powder technology has consistently demonstrated the capability to enhance the performance of metal additive manufacturing processes, supporting both production speed and part reliability. APWORKS has focused on lightweight design and advanced material development since its founding as an Airbus subsidiary. The company’s flagship alloy, Scalmalloy, combines exceptional strength, corrosion resistance, and low weight—characteristics essential to demanding applications in aerospace, automotive, and motorsport. Materials and process innovation remain central to APWORKS’ work, supporting a global client base with advanced solutions for metal additive manufacturing. “Scalmalloy will be a great addition to our line of high-performance materials for serial additive manufacturing,” said Kevin Nicholds, CEO of Equispheres. “We’re excited to be in discussions with APWORKS about producing this high-strength alloy for aluminum parts. North American supply of critical materials such as aluminum-scandium alloys is a key step toward securing the aerospace supply chain.” Jonathan Meyer, CEO of APWORKS, noted, “Equispheres is a logical choice for expanding Scalmalloy production into North America. They are widely regarded for their expertise in producing high-quality aluminum powders for additive manufacturing, and their access to domestic sources of aluminum and scandium is an important factor in supply chain resilience in an increasingly uncertain world.” Evan Butler-Jones, Vice-President of Product & Strategy at Equispheres, emphasized the broader implications: “Scalmalloy powder made in Equispheres’ North American facility will eliminate many of the adoption barriers that have historically limited the use of this alloy in critical programs. By combining the excellent properties of Scalmalloy with our proprietary powder technology, we can deliver an ideal material solution for the most demanding AM applications.” Scalmalloy test part. Photo via Equispheres. Future updates on North American Scalmalloy production and supply chain alignment will be announced as APWORKS and Equispheres move forward with the project. The initiative is seen as a significant step toward strengthening regional supply chains for advanced manufacturing, providing critical material solutions for aerospace, defense, and other industries.  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 Scalmalloy part. Photo via Equispheres. Anyer Tenorio Lara Anyer Tenorio Lara is an emerging tech journalist passionate about uncovering the latest advances in technology and innovation. With a sharp eye for detail and a talent for storytelling, Anyer has quickly made a name for himself in the tech community. Anyer's articles aim to make complex subjects accessible and engaging for a broad audience. In addition to his writing, Anyer enjoys participating in industry events and discussions, eager to learn and share knowledge in the dynamic world of technology.

German car manufacturer BMW Group has opened a $25 million (approx. €23.3 million) Additive Manufacturing Campus in Munich, expanding its effort to industrialize 3D printing for automotive production.  While the investment is new, the direction it points to has been years in the making. The company’s AM initiatives have steadily expanded since the launch of the IDAM project in 2019, which saw BMW and its partners implement two automated metal 3D printing lines; one in Bonn and one in Munich.  Three years later, BMW also helped complete the POLYLINE project, focused on developing an automated production chain for polymer parts. Both projects, backed by the German Federal Ministry of Education and Research, were aimed at moving 3D printing from prototype labs into high-throughput, factory-floor environments. “Additive manufacturing is already an integral part of our production system,” says Milan Nedeljković, BMW AG Board Member for Production. “This new facility will enable us to further integrate and scale these technologies.” A section of the POLYLINE project with automated systems of Grenzebach, DyeMansion and EOS, located at the Additive Manufacturing Campus of BMW. Photo via DyeMansion. 3D printing at BMW The new campus brings many of these efforts under one roof. Around 50 3D printers have been installed at the site, with another 50 already operational across BMW’s global network. Eighty specialists are currently stationed at the Munich facility, where they’re focused on tool-less production processes with an emphasis on reducing development time and cost. In addition to its production and prototyping roles, the campus will serve as a research and training center. BMW says it will support further development of automated workflows established through IDAM and POLYLINE, ranging from quality assurance integration to series production. The company has also been active outside its own walls. In parallel with building its internal infrastructure, the car manufacturer has invested in startups such as Carbon, Desktop Metal (now a subsidiary of Nano Dimension), Xometry, and ELISE, with a focus on digital manufacturing, according to Design Engineering. Other efforts to embed 3D printing deeper into manufacturing include BMW’s collaboration with Laempe Mössner Sinto, announced late last year. Through this partnership, six fully automated binder jet systems were installed at BMW’s foundry in Landshut, enabling large-scale production of sand cores for six-cylinder engine components. Additionally, the Munich campus is expected to become a central training hub. The aim is to help employees worldwide adapt to shifting design standards, part qualification methods, and factory operations shaped increasingly by AM. Laempe sand 3D printers. Photo via Laempe. Automotive 3D printing facilities Walking a similar path as BMW, other companies also invested in their own 3D printing facilities for automotive production. One month ago, Bosch opened a €6 million metal AM facility at its Nuremberg plant, centered around a Nikon SLM Solutions NXG XII 600 3D printer. With the ability to produce up to 10,000 kg of parts per year at speeds of 1,000 cm³/h, the setup is designed to make production faster and more flexible.  By eliminating the need for tooling and reducing material waste, Bosch aims to shorten development timelines and support more sustainable practices. While initially focused on automotive components, the company also sees potential in energy and aviation applications. Few years ago, American carmaker Ford opened an Advanced Manufacturing Center in Redford, Detroit, integrating 3D printing, collaborative robots, digital manufacturing, and augmented reality. At the time of the launch, the facility was used to produce components for the Ford Shelby Mustang GT500, including two 3D printed brackets that secured the brake line.  These parts helped reduce production costs while supporting the vehicle’s hydraulic brake system. Equipped with a 700hp 5.2-litre V8 engine, the GT500 was described as the most powerful sports car Ford had built and was showcased at the North American International Auto Show in Detroit in January 2019. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows a section of the POLYLINE project with automated systems of Grenzebach, DyeMansion and EOS, located at the Additive Manufacturing Campus of BMW. Photo via DyeMansion.

At this year’s RAPID + TCT show, polySpectra, an advanced materials company known for its durable Cyclic Olefin Resins (COR), and Tethon 3D, a U.S.-based ceramic additive manufacturing specialist, have jointly launched ThOR 10, a new composite photopolymer resin engineered for industrial 3D printing. The new material combines polySpectra’s thermally stable, impact-resistant COR platform with Tethon’s proprietary ceramic fillers, delivering a resin suited for demanding end-use parts. ThOR 10, named as a portmanteau of “Tethon” and “Olefin Resin”, is the first in a series of composite resins intended to close the gap between prototyping materials and functional, production-grade components. It targets sectors such as aerospace, automotive, electronics, and tooling, offering a potential alternative to traditional glass-filled thermoplastics like nylon, PEEK, and PBT. “Filled polymers are an incredibly important category of engineering materials,” said Raymond Weitekamp, PhD, Founder and CEO of polySpectra. “We’re excited to bring this new level of thermomechanical performance to resin 3D printing.” The composite’s toughness is underpinned by a Notched Izod impact strength of 55 J/m and elongation at break above 20%, while its glass transition temperature (Tg) of 131°C enables durability under sustained heat. Tethon 3D CEO Trent Allen emphasized the significance of combining the company’s ceramic expertise with polySpectra’s base resin platform. “These efforts are necessary to drive additive manufacturing forward and set new standards in impact resistance and thermal stability.” 3D printed ceramic parts. Photo via Tethon 3D. Advanced performance for functional parts ThOR 10 is compatible with both desktop and industrial DLP/LCD 3D printers, and builds upon COR’s reputation as a durable material designed to address the historic brittleness of photopolymer prints. According to the companies, the ceramic reinforcement significantly boosts both impact resistance and stiffness, positioning ThOR 10 for use in production-grade components across sectors such as aerospace, automotive, and electronics. Market availability and technical specifications ThOR 10 is now available in both 385nm and 405nm formulations, with orders open through polySpectra and Tethon 3D. PropertyValueMaterial TypeCeramic-filled Cyclic Olefin Resin (COR)Filler Content10% glass-filled compositeNotched Izod Impact Strength55 J/mElongation at Break>20%Tensile Modulus2.0 GPaGlass Transition Temperature (Tg)131°C (268°F)Chemical ResistanceHigh (inherent to COR chemistry)Compatible Wavelengths385 nm and 405 nmPrinter CompatibilityIndustrial and desktop DLP/LCD 3D printersApplicationsGears, impellers, tooling inserts, electronics enclosures, brackets, mounts, housings, fluidic manifoldsAvailable FrompolySpectra and Tethon 3D For full material details, view the ThOR 10 technical datasheet. Advancements in ceramic AM and photopolymer composites The launch of ThOR 10 reflects a broader industry shift toward composite photopolymers that deliver production-level performance. Ceramic-filled resins have gained traction for their ability to withstand thermal and mechanical stress, expanding the range of feasible applications in additive manufacturing. Tethon 3D, for instance, has been expanding its ceramic AM capabilities, most recently through its acquisition of TA&T, enabling in-house sintering and resin development. At the same time, polySpectra continues to develop COR based materials that offer enhanced toughness and heat resistance for both prototyping and end-use production.What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? 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 3D printed part made from COR Zero. Photo via polySpectra.