Prusa Research, a leading manufacturer of 3D printers based in Prague, has announced the release of the CORE One, a fully enclosed CoreXY 3D printer featuring active chamber temperature control. This launch represents Prusas strategic move to enhance its position in the prosumer market amidst increasing competition.Combining a compact design with a substantial print volume of 250220270 mm, The CORE One caters to a wide range of printing needs from rapid prototyping to precise dimensional accuracy. Unlike setups that require multiple machines for different tasks, the 3D printer integrates these capabilities into a single unit. Key features include an exoskeleton design for enhanced rigidity, active temperature control reaching up to 55C, and the ability to print PLA and PETG with the enclosure closeda feature not commonly found in current market offerings.The new Prusa Core One. Photo via Prusa Research.Josef Prusa, founder of Prusa Research, emphasized the printers all-in-one functionality: With the CORE One, you wont need separate printers for different tasks. Its designed to deliver high quality and speed across a wide range of materials.Designed to complement the existing MK4S model rather than replace it, the CORE One allows for seamless integration and upgrade paths. Prusa Research will continue to support the MK4S with firmware updates and new accessories. The backward compatibility enables MK4S owners to upgrade to the CORE One using a conversion kit available in March 2025, promoting sustainability and extending the life of existing equipment.Upgrade the Prusa MK4S to Core One with the conversion kit. Photo via Prusa Research.The printer features Prusas proprietary Nextruder, known for exceptional print quality and reliability. Enhanced with 360 cooling from the MK4S, the Nextruder improves overhang performance, reducing the need for support structures and conserving material and time. Additional features include dual fans for active temperature control, maintaining optimal conditions for various filament types.Prusa Research is also expanding the CORE Ones ecosystem with new accessories like the Buddy3D Camera and advanced filtration systems, expected to be released alongside the printer. These additions aim to enhance functionality and user experience, catering to both hobbyists and industrial users.Prusa Research will showcase the CORE One at FormNext 2024 in Frankfurt, located at Hall 12.1, Stand G39. The printer is scheduled to begin shipping in January 2025, with an introductory price of $1,199 USD (VAT excl.) and 1,349 EUR (VAT incl.). Conversion kits for existing MK4S owners will be available in March 2025, allowing users to transform their MK4S printers into CORE One models.Close-up of the Prusa CORE Ones extruder and belt-driven CoreXY mechanism. Photo via Prusa Research.Prusa CORE One: Technical ParametersCategoryHighlightsMeasurementsBuild Volume: 250 x 220 x 270 mm (9.8 x 8.6 x 10.6 in)Dimensions: 415 444 555 mm (16.3 17.5 21.8 in), Weight: 22.5 kgElectronicsCustom 32-bit xBuddy Mainboard with STM32, Trinamic 2130 DriversExtruderDirect Drive Nextruder with 10:1 Planetary Gear System, High-Flow Nozzle (0.4 mm)All-metal hotend with 360 coolingTemperatureMax Nozzle: 290 C (554 F), Heatbed: 120 C (248 F), Chamber: 55 C (131 F)Controls3.5 Touchscreen, Automatic Bed Leveling, Prusa Connect and Mobile App supportConnectivityEthernet, Optional Wi-Fi with NFCSensorsDual Filament Sensors, Load Cell for precise calibration, Door SensorPrintingMagnetic Heatbed, Input Shaper, Supports PLA, PETG, ABS, ASA, Flex, and morePower240W PSU, Power Panic featureYour voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured image shows the Exoskeleton of the Prusa Core One. Image via Prusa Research.

Cleaning and surface finishing systems manufacturer DyeMansion has introduced three new post-processing products at Formnext 2024 under the theme it just WorX.Having reported the increased use of Powerfuse S technology, these additions from DyeMansion aim to enhance flexibility, sustainability, and return on investment (ROI) for both new and established users in the additive manufacturing sector.DyeMansion is showcasing these offerings at the tradeshow, where attendees can explore the solutions in detail at Booth C31, Hall 12.1. Demonstrations are available for visitors interested in gaining a deeper understanding of the products and their capabilities.The Powershot X system. Image via DyeMansion.Elevated post-processing capabilitiesOne of the key launches is the Powershot X, which brings a new level of versatility to automated blasting systems. Building on the reputation of the widely used Powershot series, this system integrates three modes: PolyShot Cleaning (C), Surfacing (S), and a combined Cleaning & Surfacing (C&S) process.These capabilities allow manufacturers to adapt quickly to changing production demands while maintaining efficiency. Designed for scalability, the system supports growth in manufacturing environments, and its cost-effective design ensures faster ROI by lowering operational expenses while delivering high-quality part finishing.For manufacturers focusing on black dyeing, the upgraded DM60 Reservoir introduces a resource-efficient approach tailored to meet varying volume requirements. Built-in sensors precisely manage water usage, accommodating dyeing needs ranging from small to extra-large batches.By enabling up to 12 reuse cycles of black dyeing water, the system reduces resource consumption significantly. Additionally, residual heat from previous cycles helps shorten process times by up to 30%, cutting costs by more than 50%. These features position the DM60 Reservoir as an eco-friendly and economical solution for modern manufacturing needs.Also debuting is the Automotive ColorsX range, designed to meet the specific demands of the automotive industry. These colors offer exceptional UV and heat resistance, ensuring durability and long-lasting performance in applications such as car interiors.Alongside durability, the range provides extensive customization options, allowing manufacturers to align colors with brand-specific requirements. The colors achieve grey scale values up to four times higher than previous standards, making them suitable for high-performance environments while reducing costs and enabling broader applications.The Automotive ColorsX range. Photo via DyeMansion.Exploring post-processing solutions across 3D printing sectorDyeMansions latest releases join a growing portfolio of post-processing solutions introduced across the industry.In March 2024, Additive Manufacturing Technologies (AMT) introduced the PostPro DPX, a compact and cost-effective depowdering system designed for non-industrial 3D printing. Priced at 15,995, it complements its predecessor desktop-focused PostPro SFX and features a 10-liter basket, ionization unit, and powerful filtration for efficient and safe post-processing.Tailored for industries like dental, jewelry, and prototyping, the DPX is ideal for businesses using desktop printers from brands like Formlabs and Sinterit. AMT also offers a bundle combining the DPX with the SFX chemical vapor smoothing system for 35,995, providing a comprehensive solution at a reduced cost.Last year at Formnext, Formlabs unveiled the Fuse Blast, an automated post-processing solution for Selective Laser Sintering (SLS) 3D printing. As part of the Fuse Series ecosystem, Fuse Blast reduces post-processing time by 80%, transitioning parts from printed to finished in just 15 minutes.Its features include automated tumbling for hands-off cleaning, an in-line ionizer to prevent dust resettlement, and pre-programmed routines for various materials. Alongside the hardware, software updates further enhance print speed, powder efficiency, and part resolution.Catch up on all the news fromFormnext 2024.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the Powershot X system. Image via DyeMansion.

Metal 3D printer manufacturer Meltio has introduced the Meltio Engine Blue integration kit at Formnext 2024.Designed to integrate seamlessly with industrial robotic arms and vertical machining centers, this new system aims to enhance the process of metal 3D printing parts. Leveraging factory-calibrated Blue Laser technology, it offers substantial improvements in productivity, energy efficiency, and ease of use, building on the foundations of the Meltio Engine V3.In Hall 12.0 Booth C119, the manufacturer is demonstrating Meltio Engine Blues versatility with metal parts made from marine bronze, copper, dual-wire materials, and a build plate integrating tool steel, mild steel, marine bronze, and stainless steel, highlighting its capability for multi-material and complex material production.The new Meltio Engine Blue represents a crucial breakthrough in Meltios directed energy deposition (DED) technology, designed specifically to respond to the current demands of the manufacturing industry around the world. For our industrial customers, the Meltio Engine Blue represents a significant improvement in reliability and deposition rate, enabling increased production speed and quality, explains Meltio Product Manager, Alejandro Nieto.Jet engine exhaust created using Meltio Blue Engine. Image via Meltio.Faster metal parts production and streamlined operationsBoasting a deposition rate that is up to 3.5 times higher than its predecessor and a 30% reduction in energy consumption, this system highlights its efficiency in metal AM processes. Simplified installation and maintenance are achieved through a compact, lightweight design that eliminates components like fiber optics and collimators.These updates enhance operational reliability, allowing the creation of high-density, durable metal parts for industries like aerospace, automotive, defense, energy, maritime, mining, and oil and gas, with various materials that can be processed with precision.Nieto emphasized that the development of the Meltio Engine Blue involved over two years of meticulous work. The engineering team collaborated closely with partners and integrators to address challenges identified with the previous V3 system. Key industry demands, such as reducing maintenance time, enhancing reliability, and improving deposition rates, guided the development process.Several technical upgrades play a vital role in the advanced capabilities of Meltio Engine Blue. A dual wire-feeding system, featuring internal motors and a 10-meter wire roller liner, ensures stable material handling for uninterrupted operation. High-quality servo motors on the T0, T1, and Z axes, along with encoders on feeders and an absolute encoder on the Z axis, contribute to precise and stable deposition.Process oversight is further enhanced by an integrated melt pool camera, which allows real-time monitoring of operations. Customers will also benefit from features such as quick-connect components for easier installation, screen options in 27 and 17 sizes, and an optional deployable deposition head for expanded applications.In addition, safety measures have been upgraded to meet the highest industrial standards. A service mode key, coupled with redundant internal safety systems, ensures secure operations in demanding environments.By reducing maintenance needs and eliminating frequent laser alignment, the system minimizes downtime while improving operational efficiency. A 30% reduction in energy consumption compared to the previous version helps lower operating costs and contributes to sustainability goals.As per Meltio, higher deposition rates and reduced maintenance requirements make the system a practical choice for manufacturers aiming to optimize production workflows without compromising quality.A nozzle guide vane. Image via Meltio.Technical specifications of the Meltio Engine BlueLaser SystemBlue Laser (Higher absorption and power efficiency; wider range of compatible materials than IR) 1000W 9 x 450 nm direct diode lasersPrintheadRobot Mounted 20.5 to 23 kgPrinthead Size (W x D x H)262 x 272 x 572 mmControl UnitWall mounted, air-cooled 80.5 kg 600 x 300 x 800 mm. Separate wall mounted 27 HMICoolingWater-cooled deposition head, chiller includedPrint Envelope (W x D x H)Depending on robots reachProcess ControlMelt Pool Camera & Closed-loop wire modulationPower Input200/240 V 3W+PE 380/415 V 3W+N+PEPower Consumption9,2 kW peak 2-5 kw avgSlicer SoftwareMeltio Space 1-year subscription includedFeeder SystemQuad-point traction servomotor feeder, frictionless linersWire FeedstockDiameter: 0.8-1.2 mm / Spool Type: 8S300 External wire drum readyProduct ConfigurationsSingle or dual wireCompatible MaterialsStainless steels, carbon steels, tool steels, nickel alloys, titanium, copper alloys, gold alloys and moreCatch up on all the news fromFormnext 2024.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows a jet engine exhaust created using Meltio Blue Engine. Image via Meltio.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

Our series profiling the most innovative 3D printing companies continues with Axtra3D. Ahead of the 2024 3D Printing Industry Awards, we caught up with Rajeev Kulkarni, Chief Strategy Officer.Axtra3D is driving 3D printing technology forward with its innovative Lumia X1 system, which leverages Hybrid Photosynthesis (HPS) and TruLayer technologies to deliver next-gen AM performance. The Lumia X1 integrates the speed and efficiency of DLP with the precision of SLA, enabling simultaneous imaging of internal and external structures for high throughput and exceptional detail. TruLayer technology ensures consistent layer curing and eliminates peeling effects, significantly enhancing print accuracy. With a wide material compatibility, including silicone and biocompatible photopolymers, Axtra3Ds solution supports diverse applications across industries such as healthcare, automotive, and consumer electronics.Axtra3D is also shortlisted for the Enterprise 3D Printer of the Year (Polymers) award.3DPI: Can you describe your 3D printing innovation and how it differs from existing technologies in the market?Rajeev Kulkarni: At the core of the Lumia X1 from Axtra3D is a breakthrough approach that eliminates the traditional trade-offs between accuracy, print speed, surface finish, and feature resolution typically encountered in conventional SLA or DLP processes. HPS combines DLP and laser imaging to simultaneously image both internal and external structures. The DLP handles large areas for high throughput, while the laser focuses on intricate details and external walls, ensuring high resolution.TruLayer technology precisely controls the layer heightwhether 25 microns, 50 microns, or morebefore curing, eliminating the need for overcuring and preventing any risk of delamination. By using the exact amount of energy required to cure each layer, TruLayer minimizes light bleeding from side walls, enhancing print accuracy. Additionally, the horizontal separation between the film and glass virtually eliminates peeling effects, ensuring zero hydrostatic forces during separation and promoting optimal print quality.450 PP parts produced with ceramic mold inserts printed using HPS on the LumiaX1. Photo via Axtra3D.3DPI: What specific problem does your innovation solve, and what makes it a groundbreaking solution in the 3D printing space?Rajeev Kulkarni: HPS provides SLA-quality parts at DLP/LCD speed. It combines the best aspects of throughput, accuracy, feature resolution, and surface finish from each technology into one system.The dual imaging approach allows the printer to produce exceptionally detailed parts at up to 20 times the throughput of conventional SLA.These combined innovations enable the same system to print everything from micro stents to large 19 molds at speeds up to 20 times faster than conventional SLA. Additionally, the Lumia X1 supports a wide range of materials, including low- to high-viscosity photopolymers and specialized materials like silicone and bio compatibles, making it ideal for industrial and medical applications.3DPI: Which industries or sectors do you see your technology bringing the most benefits?Rajeev Kulkarni: LumiaX1 technology has targeted and successfully executed multiple applications and solutions within the industrial and healthcare sectors.For example, concept injection molding with ceramic mold inserts. Axtra3Ds Lumia X1 HPS 3D printer, paired with Ultracur3D RG 3280, offers a faster, cost-effective alternative by enabling high-quality mold insert production in a single day. This process can deliver a finished part within an 8-hour workday, with production costs under $100 per set, making it ideal for rapid prototyping and low-volume production of PP, PE, TPE, TPU and ABS. The high-stiffness, temperature-resistant material supports hundreds to thousands of injection cycles, allowing for quick, affordable iterations and the production of complex designs.Another application is direct true silicone 3D printing. True silicones unique rheological properties create challenges in achieving the ideal viscosity and flow for accurate 3D printing, leading to potential defects like poor layer adhesion or incomplete curing. TrueSil-X50, a 100% pure, biocompatible silicone material optimized for Lumia X1s Hybrid Photosynthesis (HPS) technology, allowing high-precision and high-resolution parts suitable for industrial and healthcare applications. The combination achieves resolutions previously difficult in photopolymerization, which allow for reliable, isotropic end-use parts. This has enabled robust applications across industries, including industrial components like sealants, connectors, and grippers, and healthcare products such as anatomical models, wearable devices, implants, and cosmetic applicators.End-use electronic connectors are a further application. The printers advanced technology is redefining the manufacturing process for these critical components, addressing industry challenges and setting new standards of fast throughput (60 connectors in under 3 hours), high accuracy, repeatability, and fire-retardant properties. The crisp edges and consistent hole diameters make it ideal for precise electronic components. The result is connectors with crisp edges and highly accurate hole diameters, often down to 300 microns.For functional prototypes and low volume production, the combination of throughput, surface finish, accuracy, and resolution ensures that parts produced by the Lumia X1 are comparable to injection-molded parts. Its ability to handle large parts (up to 499mm) with fine features and smooth surfaces is invaluable for prototyping and low-volume manufacturing. From engine parts and interior elements in automotive to lightweight, high-strength aerospace parts, thin-walled components for durable goods, and precise casings and connectors for consumer electronics, our customers have applied it across a myriad of applications.Axtra3D also has applications for dental solutions. The dental industry demands precision, biocompatibility, and rapid turnaround. The dental labs benefit significantly from the advanced capabilities of the Lumia X1 to create models, aligner molds, splints, surgical guides, and dentures. HPS technology boosts productivity delivering 40% more throughput than other market solutions.3 kg, mold insert with a 20-micron flat mating surface across the entire print area. Photo via Axtra3D3DPI: What milestones have you achieved, and what are your next major goals?Rajeev Kulkarni: Since the product was launched 18 months ago and the completion of the beta program, the company has sold over 30 printers. Revenue has consistently doubled each year from 2022 to 2024. It has been adopted by industry leaders, including Protolabs, Toyota Motors USA AM, Estee Lauder, Becton Dickinson, Molex, and 10+ service bureaus worldwide.The company has expanded globally with operations in the US and EU, and sales across North America, the EU, and Japan.Strategic partnerships have been developed with top photopolymer material companies like AM Forward, NextDent, 3D Systems, Henkel Loctite, Pro3Dure, and Keystone, resulting in the launch of over 20 materials.The companys patent portfolio continues to grow, with 15 patents currently granted.Secured $9.75M in Series A funding at times when the AM industry has been struggling.Axtra3Ds immediate goals are to scale the customer support organization for deeper partnerships with customers, scale outside US, EU and Japan and broaden our product offering.3DPI: Is your 3D printing solution scalable for mass production, and if so, what steps have you taken to ensure scalability without compromising quality?Rajeev Kulkarni: Quality of product and design is critical and at the heart of our solutions. The Axtra3D printer features a modular architecture that enables easy scalability, allowing it to handle increased production volumes while maintaining consistency. With compatibility across a wide range of high-quality materials and strategic partnerships, the printer is adaptable to industries like automotive, healthcare, and consumer goods. Coupled with optimized software, real-time quality control, and predictive maintenance, this system ensures high performance, minimal downtime, and consistent output at scale.3DPI: Can you say something about the development process behind your innovation, including key challenges and how they were overcome?Rajeev Kulkarni: The HPS and TruLayer innovations were developed specifically to overcome the challenges of traditional SLA and DLP and by merging their strengths. After two years of intensive R&D, these technologies were successfully integrated.HPS addressed the challenge of print throughput and precision. This was particularly complex, as both light sources had to image coaxially and in perfect sync with identical frequency. Through systematic experimentation and innovation, this was achieved, enabling enhanced print speed and precision.Our TruLayer innovation goes beyond high resolution, it was crucial to produce large, flat surfaces with 20-micron flatness. TruLayer technology overcame this by eliminating hydrostatic forces and peel-off constraints between cured layers, allowing precise production of expansive flat geometries.Additionally, the company pioneered a unique slicing engine and software that simultaneously generates raster scan data and image data, utilizing both datasets concurrently to cure each layer. This dual-data approach enhances precision and control, contributing to superior print quality and consistency.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.

Metal 3D printer manufacturer Nikon SLM Solutions has unveiled its redesigned SLM 280, SLM 280 Production Series (PS), and SLM 500 machines, offering advanced features aimed at increasing productivity and reliability.With a guaranteed minimum uptime of 85% and a track record of exceeding 90% uptime in existing installations, these systems reflect ongoing progress in metal additive manufacturing. Alongside these updates, the new Picture Perfect Pro Plan service package has been introduced, complementing the machines with extended support. Both offerings are being showcased atFormnext trade show this week in Hall 12.0, Booth D119.The SLM 280 Production Series system. Image via Nikon SLM Solutions.Streamlined design meets elevated productivityFeaturing a sleek exterior redesign and technological upgrades, the SLM 280, SLM 280 PS, and SLM 500 models incorporate advanced recoater brushes, Permanent Filter Modules (PFM), and powerful 700W lasers. These enhancements are crafted to simplify workflows while raising performance benchmarks in metal AM. Each feature is part of a broader strategy to streamline operations and ensure a seamless experience for users.Supporting these developments, the Picture Perfect Pro Plan offers a robust package of benefits for customers in North America and Europe.Existing clients upgrading their machines or renewing their service contracts for five years can also take advantage of this plan. Notably, this initiative introduces an industry-first uptime commitment for mid-size and larger systems, reinforcing Nikon SLM Solutions dedication to reliability and precision.According to the company, this plan includes several key benefits, beginning with a guaranteed minimum of 85% uptime for models such as the SLM 280, SLM 280 PS, SLM 500, and NXG series.Customers currently using these systems report uptime rates exceeding 90%, which highlight the machines dependable performance across multiple sectors. Operational efficiency is further supported by essential production items, including intuitive handling devices for safe and efficient part management. In addition, buyers of the SLM 500 will receive additional build cylinders to prevent interruptions in production cycles.To enhance digital optimization, customers will also gain access to five years of software solutions, including SLM.Link, SLM.Quality, and Free Float. Tailored powder supply contracts ensure uninterrupted workflows, while Nikons Total Care program offers comprehensive service and support over the same five-year period. These measures collectively ensure operational reliability and consistency for users.The SLM 500 3D printing system. Image via Nikon SLM Solutions.Shaping metal AM with robust systemsNikon SLM Solutions latest developments reflect ongoing progress in metal AM, with other industry players introducing systems tailored for advanced applications and high-performance production. Recently, metal 3D printer manufacturer Eplus3D introduced the EP-M4750, a metal 3D printer designed for large-scale batch production in industries like aerospace, automotive, and tooling.Utilizing Metal Powder Bed Fusion (MPBF) technology, it supports a variety of metals, including titanium and aluminum, and offers a build volume of 450 x 750 x 530 mm. Equipped with dual or quad 500 W fiber lasers (optional 700 W), it achieves print speeds up to 70 cm/h. Features like adjustable layer thickness, advanced gas flow, and proprietary software streamline production, making the EP-M4750 ideal for high-output industrial applications.Additionally, large-format robotic 3D printer manufacturer Caracol has introduced Vipra AM, its latest large-format additive manufacturing (LFAM) 3D printing system, at Formnext 2024. Designed for large-scale metal 3D printing, Vipra AM combines robotic deposition and automation to produce complex industrial components with precision and efficiency.Offering two configurations, Vipra XQ (Extreme Quality) focuses on high precision for aerospace and energy sectors, while Vipra XP (Extreme Productivity) enhances throughput for automotive and marine industries. Supporting hybrid workflows, the system reduces waste and lead times.Catch up on all the news fromFormnext 2024.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the SLM 280 Production Series system. Image via Nikon SLM Solutions.

Multinational printing firm HP has introduced a range of innovations in polymer and metal AM at Formnext 2024, aiming to improve cost efficiency, scalability, and accessibility in additive manufacturing.Key announcements include a new flame-retardant polymer material, advanced software tools for streamlining workflows, and strategic collaborations to enhance metal printing applications. These efforts are designed to address challenges in adoption and expand the technologys impact across industries, including automotive and footwear production.Attendees at the tradeshow can visit HP at Hall 12.1, Stand D41, to explore developments and participate in discussions on additive manufacturing topics.Ken Burns, VP of Commercial at Forecast 3D said, As an early customer, Forecast 3D expects a 20% savings in total build costs with the HP Build Optimizers unique nesting rules for MJF. In addition to these total build cost savings, we anticipate a 21% improvement in printer utilization with the HP Build Optimizers ability to increase packing density and parts per build.HPs booth at Formnext. Photo via HP 3D Printing.New materials and tools for additive manufacturingAmong the highlights was the introduction of HP 3D HR PA 12 FR, a halogen-free, flame-retardant material developed in partnership with Evonik.Scheduled for availability in early 2025, the material features a 50% reusability ratio that helps reduce production costs while ensuring high-quality aesthetics. It is geared toward industrial and consumer electronics applications and reflects HPs emphasis on sustainable practices, being produced using renewable energy.Another significant development is the launch of HP 3D Build Optimizer, an automated tool designed to improve part nesting, reduce build costs, and maintain quality standards. Set for release in 2025, this tool complements HPs ongoing efforts to optimize production workflows.Additionally, the company announced a partnership with Autodesk, resulting in the Autodesk Fusion Bundle. This integrated CAD/CAM and build preparation solution will be bundled with all new Multi Jet Fusion (MJF) and Metal Jet printers, offering users a one-year license to Autodesk Fusion.Collaborative efforts with software providers have further enhanced HPs ecosystem. Integration of the HP Lattice Library into Magics expands design capabilities for MJF applications, while a partnership with Fabrex introduces an AI-powered platform to streamline build preparation, order management, and tracking for HP 3D printer users.Initiatives for metal AM accessibilityIn metal 3D printing, HP revealed new configurations for the Metal Jet S100 platform, tailored to meet diverse production requirements. These configurations, expected to launch in 2025, are designed to lower adoption costs and provide scalable solutions for research centers, OEMs, national laboratories, and startups exploring metal binder jetting technology.Collaborations with industry leaders are reinforcing HPs progress in the sector. A partnership with ArcelorMittal combines expertise in additive manufacturing and sustainable steel production to lower costs and expand the use of 3D printed steel in automotive and other sectors.Meanwhile, efforts with Eaton are advancing nitrogen-enhanced sintering, which improves mechanical properties in 316L metal parts, and the S100 Powder Processing Solution, designed to reduce costs and enhance binder jetting yield.Adoption of metal AM is further supported through the establishment of a Metal Jet Adoption Center in Barcelona, created in partnership with AMES. This facility integrates HPs 3D printing technology with AMES metallurgical expertise, enabling customers to transition efficiently from prototyping to full-scale production.Moreover, HP also introduced the Leading Minds Consortium, an alliance among industry giants such as 3D Systems, Ansys, EOS, Materialise, Nikon SLM Solutions, Renishaw, Stratasys, and Trumpf. This initiative aims to address challenges such as cost and system integration, fostering wider adoption of industrial 3D printing.In the sporting goods sector, HP has partnered with Something Added to convert the D-factory into a hub for footwear manufacturing. This initiative aims to leverage additive manufacturing for cost-effective, large-scale production.The Leading Minds Consortium. Photo via HP 3D Printing.Spotlight on industry innovations in Formnext 2024This years tradeshow is witnessing AM industry giants with unique offerings at the event. Reportedly recently, electronics 3D printer manufacturer Nano Dimension is showcasing its Fabrica software 3.2.0, which enhances micro 3D printing speeds by 70% while optimizing workflows for R&D and prototyping.Alongside this, the company also introducing Ataru, a resin offering advanced thermo-mechanical and dielectric properties, tailored for demanding sectors like electronics, aerospace, and automotive. Demonstrations will also highlight the Admatec series ability to 3D print intricate technical ceramics, with applications spanning medical devices, tooling, and more at Hall 11, Stand D22.Additionally, US-based 3D printer manufacturer 3D Systems has introduced a diverse range of 3D printing technologies and materials at the event, tailored for industrial workflows. Among the key innovations is the PSLA 270 SLA system, designed for creating mid-sized parts with speed and precision.Complementing this are the Wash 400/Wash 400F and Cure 400 post-processing solutions, which streamline resin cleaning, and advanced materials such as Figure 4 Rigid Composite White, ideal for demanding applications. Additional developments include the SLS 380 with precise thermal control and new materials for SLS and MJP technologies. Alongside these developments, the company is also conducting presentations on different topics across various stages.Catch up on all the news fromFormnext 2024.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the Leading Minds Consortium. Photo via HP 3D Printing.

Nike, a global leader in athletic footwear and apparel, showcased its new Air Max 1000 at ComplexCon in Las Vegas. This is the companys first shoe produced almost entirely through 3D printing. The project was developed in collaboration with Zellerfeld, a Berlin-based company known for its expertise in 3D-printed footwear, which emphasizes customization and sustainability. While the shoes are not yet available to the public, 1,000 pairs were made accessible through a raffle preorder at the event.Inspired by the original Air Max 1 from 1987, the Air Max 1000 retains the visible air cushion in the heel, a signature feature of the line. Unlike traditional models, the air cushion itself is not 3D printed. Instead, the shoe employs a single flexible material created through 3D printing. This material varies in density and texture, providing a firm outsole for support and a more flexible upper for comfort. The design eliminates the need for laces, allowing the shoes to be easily slipped on and off.A side view of the 3D-printed Nike Air Max 1000 highlights its intricate detailing and flexible structure. Photo via Nike.John Hoke, Nikes Chief Innovation Officer, highlighted the significance of this advancement: The Air Max 1000 allows us to explore manufacturing solutions that were previously impossible, opening up new creative possibilities. The precise contouring achieved through 3D printing was unattainable with conventional manufacturing methods, enabling more intricate and customized designs.Initially showcased in a bright red colorway, additional variants in orange, white, blue, and black with a green air cushion were later revealed at ComplexCon. Pricing details remain undisclosed, but similar 3D-printed models on Zellerfelds website range from $159 for sandals to nearly $400 for high-tops. Nike has not announced plans for a broader release, keeping the Air Max 1000 exclusive for now.The Nike Air Max 1000 offers a bold and innovative design crafted with advanced additive manufacturing techniques. Photo via Nike.3D Printings Role in Shaping Footwear ManufacturingNikes Air Max 1000 reflects broader trends in 3D printed footwear, where the balance between scalability and customization is a critical focus. Elastium, a 3D printing footwear startup, recently partnered with LaLaLand, Californias largest shoe manufacturer, to implement hybrid production models. Their No-MMOQ (Minimum and Maximum Order Quantity) approach combines 3D printing with conventional manufacturing to cut production costs by up to 80%. The collaboration allows for localized, on-demand production, addressing challenges like high investment costs, supply chain inefficiencies, and the need for sustainable practices.Meanwhile, Lore Cycle, in collaboration with Ohio-based Lubrizol, has developed the Lore Two, a fully customized cycling shoe. Using 3D scans of individual feet, Lubrizols 3D printing division creates a thermoplastic polyurethane (TPU) upper tailored to each riders biomechanics. This approach ensures optimal fit, power transfer, and comfort.Robert Karklinsh, Founder of Elastium. Photo via Elastium.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive contentFeatured image shows The Nike Air Max 1000. Photo via Nike.

In the build-up to the 2024 3D Printing Industry Awards, we take a closer look at some of the enterprises nominated as leaders in the additive manufacturing sector.Dr. Olga Dr. O Ivanova, Ph.D., is the Director of Applications & Technology at Mechnano, LLC. Specializing in advanced material science, Dr. O and her team have developed DFunc technology, a pioneering solution that prevents the issue of carbon nanotube (CNT) agglomeration, thereby enhancing the base material properties and enabling features like conductivity. By optimizing electrostatic discharge (ESD) performance, Mechnano addresses critical challenges faced by industries such as electronics and healthcare, where inconsistent ESD can lead to equipment damage and safety hazards. The company is poised to expand its influence by developing versatile, next-generation materials.Read more about this years 3D Printing Industry Awards, including Start-up of Year, and leading innovations and technology. Dont forget to vote!3DPI: Can you describe your 3D printing innovation and how it differs from existing technologies in the market?Dr. O: Our technology, known as DFunc, is designed to target the innate tendency of carbon nanotubes to agglomerate. By achieving a distinct state and making modifications to the sidewalls to prevent re-agglomeration, we are able to improve the performance of the base materials and unlock additional properties such as conductivity. This, in turn, broadens the range of applications for additive manufacturing materials. Competitors in the market utilize agglomerated CNTs, leading to inconsistent performance and failure points in fabricated components.The difference in the CNT dispersion quality achieved by Mechnano compared to that of competitor. Microscopy images by Mechnano.3DPI: What specific problem does your innovation solve, and what makes it a groundbreaking solution in the 3D printing space?Dr. O: Dfunc in additive manufacturing (AM) materials serves as a crucial solution to combat the challenge of inconsistent Electrostatic Discharge (ESD) performance, ultimately preventing part failure. In certain industries, the unreliability of ESD performance in AM materials has led to a sense of disappointment, causing some to abandon the use of AM solutions altogether. Furthermore, the variability in ESD values found in injection molding materials has added to this complexity. Mechnano has taken a proactive approach by refining materials from resins to powders and pellets, strategically optimizing the ESD performance of our materials. This meticulous process ensures the materials are finely tuned to address the issue, providing a reliable solution for consistent ESD performance.3DPI: Which industries or sectors do you see your technology bringing the most benefits, and why?Dr. O: The use of Mechnanos materials is advantageous for any industry facing issues with electrostatic discharge. In the electronics sector, for instance, a major concern is the potential harm to delicate electronic components. When ESD occurs near electronic devices, it can produce a high voltage surge that exceeds their tolerance levels, resulting in irreversible damage and system malfunction. Additionally, ESD can lead to data loss in computer systems or disrupt the operation of medical devices. In addition to these technical challenges, ESD can also pose safety risks to individuals, such as electric shocks or fires in environments with flammable materials.An assembly gig fabricated with Mechnanos PK ESD SLS powder ensures reliable ESD performance across the entire component. Photo by Mechnano3DPI: Is your 3D printing solution scalable for mass production, and if so, what steps have you taken to ensure scalability without compromising quality?Dr. O: Our 3D printing material manufacturing is highly scalable for mass production due to the implementation of meticulous quality assurance and quality control protocols. We have taken proactive steps to ensure scalability without compromising quality by investing in state-of-the-art equipment, streamlining production processes, and continually monitoring and optimizing our procedures. Robust QA/QC protocols are an integral part of our production line, guaranteeing that each and every batch meets stringent quality standards before reaching our customers. By maintaining strict adherence to these protocols, we can confidently scale our production to meet increasing demands while upholding the highest standards of quality and consistency.3DPI: What milestones have you achieved, and what are your next major goals?Dr. O: At Mechnano, we take pride in the milestones we have achieved thus far. By developing a range of innovative resins that meet diverse performance targets, and by introducing powders for SLS and pellets for extrusion processes, we have significantly advanced our product offerings. Looking ahead, our next major goals include the release of two additional pellet products in the coming months. Furthermore, we are focused on expanding our portfolio beyond ESD applications, showcasing our dedication to continuous growth and innovation. Stay tuned for more exciting developments as we strive to push boundaries and meet the evolving needs of our customers in the industry.A wave solder pallet made with Mechnanos high temperature ESD resin C-Lite. Photo by Mechnano3DPI: Can you say something about the development process behind your innovation, including key challenges and how they were overcome?Dr. O: Incorporating carbon nanotubes into additive manufacturing materials poses several complex challenges that require careful attention and ongoing research efforts. The unique characteristics of carbon nanotubes, including their high aspect ratio and remarkable strength, have the potential to enhance the mechanical and electrical properties of manufactured components. However, issues such as their dispersion within the material, bonding with the surrounding matrix, scalability of production, and cost-effectiveness must be addressed for widespread adoption. Mechnano scientists are working tirelessly to overcome these obstacles through rigorous scientific research, with the goal of fully realizing the benefits of carbon nanotubes in additive manufacturing. Our efforts are focused on developing innovative techniques to improve the uniformity and distribution of nanotubes within materials, as well as optimizing manufacturing processes to ensure consistent quality and performance. By consistently pushing the boundaries of research and innovation, our team aims to transform the additive manufacturing industry and pave the way for the next generation of advanced materials.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Michael PetchMichael Petch is the editor-in-chief at 3DPI and the author of several books on 3D printing. He is a regular keynote speaker at technology conferences where he has delivered presentations such as 3D printing with graphene and ceramics and the use of technology to enhance food security. Michael is most interested in the science behind emerging technology and the accompanying economic and social implications.

The 3D Printing Industry Awards are designed to highlight both established applications of additive manufacturing and the next generation of AM. Our profiles of this years nominees for the 2024 3DPI Awards continue with a look at FIDENTIS, selected by our panel of experts, and the pubic nomination process for the shortlist in the 3D Printing Industry Awards Start of the Year.FIDENTIS, led by CEO Max Horn, is using 3D printing for dental prosthetics to address a critical supply gap in high-quality dentures. With an aging population and a retiring workforce of skilled dental technicians, FIDENTIS aims to industrialize the production of precision dental prostheses using advanced additive manufacturing techniques. A spin-off from the renowned Fraunhofer IGCV, FIDENTIS combines over 20 years of additive manufacturing expertise with insights from industry experts, like co-founder Josef Schweiger, a leading dental technician. Their innovative solutions deliver high-quality, reproducible, customizable parts that streamline dental lab workflows, reduce costs, and enhance patient satisfaction.Max Horn CEO. Photo via FIDENTIS.3DPI: What problem are you solving, and why is it important?Max Horn: Tooth loss is prevalent. The supply of high-quality dentures is limited because they are handmade by the best dental technicians. With many dental technicians retiring and an aging population, we face a supply gap of high-quality dentures. Industrial production is limited to low-quality solutions. Therefore, it is important to enable the industrial production of high-quality dentures in order to meet the rising demand.FIDENTIS Multi-Material Telescope. Photo via FIDENTIS.3DPI: Who is your target market?Max Horn: Our customers are dental technicians and dental laboratories. Our made-to-order products are delivered to dental technicians to finish the prostheses. This reduces production time, increases lab throughput, and eliminates unprofitable steps in the dental lab. Our customers receive high-quality, reproducible, customized parts that save them time and money. Dentists benefit from fewer patient visits, and FIDENTIS quality, time, and cost benefits increase patient satisfaction.3DPI: Who are the founders and core team members, and what is their experience in this industry?Max Horn: FIDENTIS is a spin-off from the Fraunhofer IGCVthe worlds leading research institute for multi-material additive manufacturing of metals. As a scientist at Fraunhofer IGCV and doctoral student at TUM, I have been researching and shaping the technology since 2017. A few years ago, Josef Schweiger, one of Germanys most renowned dental technicians, discovered the manufacturing solution, mainly used in toolmaking and aerospace, and immediately recognized its potential for the dental industry. We joined forces and, together with our colleagues, further developed the technology to process precious metals and meet the high demands placed on dental prostheses. Together, our founding team has over 20 years of additive manufacturing experience and a strong background in medical technology. We bring the perfect mix to innovate dental production with our mentors and advisors from the dental industry. Our mission is to use scalable production technologies, collaborate effectively, and create an environment that fosters talent to ensure sustainable access to products that make people smile.Founding Team FIDENTIS. Photo via FIDENTIS.3DPI: What technical challenges have you encountered so far, and how did you overcome them?Max Horn: The regulatory framework in the EU has not yet been a setback, but it is at least a major challenge. It goes without saying that patient welfare has top priority and that peoples health must not be jeopardized by new care solutions. At the same time, the legal framework and the way in which it is implemented is extremely restrictive to innovation and costs a lot of energynot just for us as a start-up. In order to counteract the shortage of specialists and rising costs in the healthcare sector as a society, we need to be more agile in our approach to innovation.FIDENTIS Multi-Material Lasermelting Technology. Photo via FIDENTIS.3DPI: Who do you consider to be the competition in this market? How does your proposition meet underserved needs or outperform?Max Horn: We do not compete with dental technicians, but rather create synergies with them by improving their efficiency and allowing them to focus on their core activities. Industrial production is at the moment limited to solutions without friction telescopes, which are critical for a secure fit in the patients mouth. Our solutions enable dental laboratories to scale their production of high-quality solutions with friction telescopes.3DPI: What milestones have you achieved, and what are your next major goals?Max Horn: In May 2024 we have secured EXIST Transfer of Research Funding of 1.6M, which enables us to further develop our technology accordingly to the needs of patients and dental technicians. We also won the 3D Pioneers Challenge in the MedTech category. The positive response from industry experts shows us that we are on the right track and motivates us to keep up the pace and drive our vision forward intensively. Our next major goal is to make our first patients smile again.FIDENTIS Robot Integration. Photo via FIDENTIS.3DPI: Is there anything else you would like to add?Thank you to everyone who supported us on our way. Without the tremendous support of experts, mentors, colleagues, and funding bodies this would not have been possible.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Michael PetchMichael Petch is the editor-in-chief at 3DPI and the author of several books on 3D printing. He is a regular keynote speaker at technology conferences where he has delivered presentations such as 3D printing with graphene and ceramics and the use of technology to enhance food security. Michael is most interested in the science behind emerging technology and the accompanying economic and social implications.

ADDIMETAL, a leader in metal additive manufacturing based in Toulouse, has unveiled its K-2-2 metal binder jetting 3D printer at the upcoming Formnext 2024 exhibition in Frankfurt. After four years of development and a year-long beta-testing phase, the new system is set to offer manufacturers a new level of precision and efficiency in producing complex metal parts.The K-2-2 is engineered for industrial-scale applications, featuring an 8-liter build volume (200x200x200 mm) that supports both small and large component production. Operating at resolutions from 360 to 1200 DPI, the printer delivers high-resolution outputs suitable for intricate metal parts. A standout feature is its expansive print head, which covers over half the build platform in a single pass, substantially reducing layer printing time and boosting overall productivity.Operator adjusting parameters on ADDIMETALs K-2-2. Photo via ADDIMETAL.Customization is a cornerstone of the K-2-2s design. It offers precise control over various printing parameters, including layer strategy, binder deposition, print speeds, temperatures, and atmospheric conditions. This granularity allows manufacturers to fine-tune the process for specific project needs, ensuring optimal results. Furthermore, the machine supports non-proprietary consumables, enabling the use of a wide range of metallic powders and binders. This flexibility not only lowers material costs but also fosters innovation by allowing the integration of third-party binders with diverse properties such as viscosity, saturation, and debinding performance.Our machines ability to use non-proprietary consumables offers unparalleled freedom to manufacturers, providing the flexibility they need to push the limits of innovation, explained Franck Liguori, CCO of ADDIMETAL. Weve designed the K-2-2 to be versatile, cost-efficient, and easy to integrate into existing workflows, making it ideal for R&D teams and industrial applications alike.JPB Systme, a prominent player in the aeronautics sector, served as an early beta tester for the K-2-2. The company reported significant improvements in both the quality and efficiency of their production processes. In just a few months, the K-2-2 delivered better results compared to other machines we have used, a JPB Systme representative commented. This positive feedback underscores the K-2-2s potential to meet the rigorous demands of high-stakes industries such as aerospace, automotive, and luxury goods.Visualization of the Orion software used in ADDIMETALs K-2-2 3D printer for precise process control and parameter adjustment. Photo via ADDIMETAL.Live demonstrations at Formnext 2024 will showcase the K-2-2s capabilities to industry professionals. ADDIMETALs CEO, Mohamad Koubar, stated, The K-2-2 bridges the gap between lab-scale research and full-scale industrial production. CCO Franck Liguori added, Our machines ability to use non-proprietary consumables offers manufacturers the flexibility they need to push the limits of innovation.The company announced the K-2-2 is available for purchase upon request, with a starting price of under 200,000. Prospective customers can request a direct quote through the ADDIMETAL website.Coming Up at Formnext 2024Caracol is set to introduce its Vipra AM platform at Formnext 2024, integrating robotic deposition technology with automation to facilitate the production of complex industrial components. Vipra AM employs Direct Energy Deposition with wire arc additive manufacturing, offering configurations tailored for both extreme quality and extreme productivity. Vipra XQ (Extreme Quality) utilizes Plasma Arc Deposition for high precision and strength, suitable for structural components in aerospace and energy sectors.Additionally, D3-AM, a subsidiary of Durst Group, is launching its LAB II ceramic 3D printer at Formnext 2024. The LAB II system combines an expanded build platform with Micro-Particle Jetting technology, designed to meet the demand for large-format, high-performance ceramic components. With a build volume of 400 x 480 x 160 mm, the LAB II supports the production of both large and high-quantity ceramic parts in a single print cycle.D3-AMs large-format LAB II ceramic 3D printer. Image via D3-AM.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured image shows an Operator adjusting parameters on ADDIMETALs K-2-2. Photo via ADDIMETAL.

Warsaw-based 3D printing service bureau 3D Lab is introducing its ATO Suite at Formnext 2024.Designed to provide researchers and manufacturers with greater control over metal powder production, the ATO Suite enables the efficient and sustainable production of high-quality spherical metal powders from various feedstocks, catering to advanced applications such as additive manufacturing.Comprising the ATO Lab Plus, ATO Noble, ATO Induction Melting System, ATO Cast, ATO Sieve, ATO Wipe, and ATO Clean, the ATO Suite is designed for seamless integration, even in space-constrained environments. Each component serves a specific purpose, collectively addressing the entire metal powder production workflow, from feedstock preparation to powder refinement and equipment cleaning.The ATO Suite. Image via 3D Lab.Live demonstrations by 3D Lab in Hall 11.0, Booth B21, will showcase how the ATO Suites modular design and novel technology enable manufacturers to produce custom powders on demand while focusing on sustainability.This launch builds on 3D Labs established expertise in material production and processing, marked by recent milestones.3D Labs powder production legacy3D Lab recently secured patents for its ultrasonic atomization technology in the U.S. and China, advancing the production of premium metal powders for AM and industrial use. In the U.S., the patent addresses methods and equipment for producing heavy metal powders, while in China, it focuses on refining evacuation processes during atomization.These patents support the development of the ATO series, with the ATO Lab Plus standing out as a modular solution for laboratory-scale production. By enhancing powder flowability, ensuring precise particle size control, and lowering oxygen levels, the technology serves critical industries such as aerospace, automotive, healthcare, and 3D printing.Building on its past successes, 3D Lab partnered with jewelry manufacturer Cooksongold in 2019 to create a compact atomizer specifically designed for precious metal powder production. This collaboration led to the development of the ATO Noble, a compact atomizer utilizing patented ultrasonic plasma atomization to optimize the handling of silver, platinum, and gold.Advancing powder production efficiency and versatilityAt the core of the suite is the ATO Lab Plus, a lab-sized ultrasonic metal atomizer that provides on-demand powder production capabilities for reactive and non-reactive metals. Its small footprint and modular design cater to businesses of all sizes, facilitating rapid alloy development with precise particle size control. For industries working with high-value materials, the ATO Noble atomizer is also included incorporating a specialized filtration system to maximize material recovery and quality.Meanwhile, the ATO Induction Melting System (IMS) introduces a versatile solution for processing diverse feedstocks, including 3D printing scraps, into high-purity powders. By combining induction melting and ultrasonic atomization, IMS ensures flexibility, enabling manufacturers to repurpose irregularly shaped materials while maintaining strict chemical purity standards.The ATO Cast vacuum casting furnace supports sustainable practices by enabling users to recycle scraps and leftover powders into new rods for atomization. This reduces costs while promoting a closed-loop material flow for zero-waste manufacturing.Enhancing workflow with complementary toolsOther features within the suite include the ATO Sieve, which ensures powder purity through ultrasonic sieving under inert gas conditions, and the ATO Wipe, an ultrasonic cleaning system for feedstock materials such as wires and rods. These tools prevent contamination and enhance the quality of atomized powders. To ensure efficient transitions between materials, the ATO Clean provides hands-free cleaning of atomizer components, minimizing downtime and the risk of cross-contamination.To further streamline operations, the Revolver Rod Feeding System enables the simultaneous atomization of up to 10 rods, maximizing productivity with precise control over feed speed and rotation. Additionally, the ATO Remote Control tablet allows real-time monitoring and adjustment of atomization processes, reducing operator workload and enhancing efficiency.The Revolver Rod Feeding System. Image via 3D Lab.A key highlight of the ATO Suite is its ability to support sustainable manufacturing through patented ultrasonic atomization technology. Users can recycle 3D printing scraps, oversized powders, and other waste materials into high-quality metal powders, contributing to resource efficiency and reducing reliance on external suppliers. This process aligns with the industrys growing emphasis on sustainability, ensuring that innovation can coexist with environmental responsibility.With its debut at Formnext 2024, the ATO Suite showcases 3D Labs approach to sustainable and efficient metal powder production, offering researchers and manufacturers practical tools for advancing their workflows.Catch up on all the news fromFormnext 2024.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the ATO Suite. Image via 3D Lab.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

Eplus3D, a metal additive manufacturing company, has partnered with German bicycle manufacturer Mve to develop the Mve Avian, an e-bike with a titanium frame built using 3D printed lugs in a monocoque structure. Using the large-format EP-M650 printer, this project achieved full battery integration within the frame, addressing complex design and production challenges through additive manufacturing (AM) and setting a new precedent for the bicycle industry.Mve, founded in Thuringia, Germany, in 1897, faced substantial obstacles in developing a titanium frame with high performance and cost efficiency. Conventional methods, including hydroforming, required specialized tooling and could not meet Mves low-tolerance specifications. Eplus3Ds EP-M650 printer, which employs Metal Powder Bed Fusion (MPBF) technology, was integral in developing custom titanium lugs and connectors without extensive tooling. The machines large-format capabilities allowed Mve to eliminate costly tooling and reduce the projects timeline by an estimated six months.The Mve Avian e-bike features a 3D-printed titanium frame developed through the partnership with Eplus3D. Photo via Eplus3D.Enis Jost, Deputy General Manager at Eplus3D, explained the significance of this approach: The cost structure is mainly determined by the uptime of the system, the maturity of the processing parameters used, and the printing speed associated with these. Since only a few grams of material are used to create the lugs, and with the increased system productivity Eplus3Ds machines provide, the raw material cost is of less effect in this case.One of the primary challenges in using titanium for 3D printing is the need for support structures, which add material costs and complicate post-processing. Eplus3D minimized the support material for each part by fine-tuning print parameters, reducing post-production time and material waste. Mve then assembled the titanium lugs using an adhesive process, avoiding welding and maintaining structural integrity while keeping the Mve Avians frame weight at 11.8 kg.The modular structure of the Mve Avians titanium frame. Photo via Eplus3D.Surface treatment posed additional technical challenges. Mve applied abrasive blasting to achieve a uniform matte finish without altering the materials strength, a choice that aligns with Mves functional and aesthetic design goals. According to the original project goals, Metal Powder Bed Fusion (MPBF) technology combined with high-strength Ti6Al4V titanium alloy was identified as the only way to meet the design, performance, and cost requirements.As Jost observed, The potential of AM in the bicycle industry can be fully explored when traditional manufacturers start to design for process and user customization, similar to other emotionally connected devices such as cars and motorcycles. By replacing traditional tooling with additive manufacturing, Mve has achieved both a durable and environmentally sustainable product.A detailed view of the Mve Avian e-bikes components. Photo via Eplus3D.Innovations in 3D Printing for Bicycle ManufacturingThe Eplus3D-Mve project is part of an industry shift toward additive manufacturing in bicycle production. INTENSE Cycles, collaborating with TRUMPF and Elementum 3D, recently redesigned the M1 downhill bikes backbone using a 3D-printed aluminum alloy with internal ribbing to improve the suspension. This configuration, created from A6061-RAM2 aluminum alloy, allows for structural features that machining cannot achieve.Lehvoss Group has also partnered with Isoco Bikes to develop the Isoco X1 e-bike, which uses a 100% recyclable thermoplastic frame. By integrating injection-molded thermoplastics, Isoco reduced the frames carbon footprint by 68% compared to aluminum while maintaining durability. The material can be recycled and reused in new high-quality components, supporting sustainability.3D printed brake lever. Photo via TRUMPF.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured image shows a detailed view of the Mve Avian e-bikes components. Photo via Eplus3D.

Massachusetts Institute of Technologys (MIT) based fashion designer Ganit Goldstein showcased a collection of garments integrated with advanced sensor technology during Boston Fashion Week 2024.Hosted at The Foundry in Kendall Square, Cambridge the event was part of the Cambridge Science Festival in collaboration with the MIT Museum. Visitors experienced the garments interactive capabilities firsthand, exploring their novel sensor-embedded designs and a Virtual Reality (VR) application that emphasized advanced engineering in wearable technology.Goldsteins Electric Skin collection featured four garments equipped with sensors and conductive materials capable of responding to environmental stimuli, such as touch and proximity. These garments demonstrated adaptive features like color and texture changes, highlighting the potential for interactive textiles.Alongside the garments, a VR application used motion tracking to transform recorded body movements into an interactive dance performance, expanding the scope of wearable systems beyond fashion.Goldsteins interactive clothing collection on display at Boston Fashion Week 2024. Photo via Goldstein.Combining tradition with technologyBuilding on her history of integrating traditional craftsmanship with 3D printing, Goldsteins earlier projects have demonstrated her continuous innovation in wearable technology.In 2018, Goldstein combined 3D printing with traditional weaving techniques to create a pair of shoes using Stratasys Connex3 multi-material 3D printer and GrabCAD software. Inspired by the Japanese ikat weaving technique, known as Kasuri, Goldstein integrated vibrant colors and intricate patterns into her design at the voxel level.These shoes were first showcased at the Arts of Fashion Foundation Fashion Show in San Francisco in 2018 and were set to appear at the Internationale Handwerksmesse in Munich in March 2019.Alongside fashion designer Julie Koerner, Goldstein collaborated with Stratasys showcasing the companys direct-to-textile PolyJet Technology as part of the EU-funded Re-FREAM project. Goldsteins work combined traditional craft methods with 3D printing to produce a Japanese-style kimono inspired by Asian embroidery and the ikat coloring technique.Using a 3D body scan and an algorithm, the design was directly mapped onto the garments surface during printing, enabling intricate patterns not achievable through conventional techniques.Expanding 3D printing in fashionAs fashion 3D printing is on the rise, many designers have been able to create sustainable designs and unique accessories.A recent example includes that of students from Arts University Plymouth and Plymouth Marine Laboratory (PML) working together to design a 3D printed dress inspired by Coccolithophores, microscopic plankton vital to the carbon cycle. Named The Plankton Lady, the dress highlights the impact of ocean warming and acidification on marine ecosystems.Made from plant-based polylactic acid (PLA) and assembled by hand, the dress was created in just ten days using the universitys Fab Lab. Showcased at prestigious venues, it is now part of The Boxs Planet Ocean exhibition, sparking conversations about climate change and ocean health until April 2025.Used on the entertainment front, Coperni introduced its iconic Swipe Bag at Disneyland Paris, produced using Rapid Liquid Printing (RLP), a process developed by MITs Self-Assembly Lab. Unlike conventional 3D printing methods, RLP allows objects to be created directly within a gel suspension, enabling soft, stretchable, and durable designs without the limitations of gravity.Made from recyclable platinum-cured silicone, the bag reflects Copernis focus on sustainable design. Moreover, this project demonstrated how advanced manufacturing techniques can blend seamlessly with creative design, demonstrating the potential for sustainable, functional fashion design.Catch up on all the news fromFormnext 2024.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows Goldsteins interactive clothing collection on display at Boston Fashion Week 2024. Photo via Goldstein.

Ceramics 3D printing OEM and process provider 3DCeram has introduced CERIA, an advanced artificial intelligence (AI) tool crafted to elevate ceramic 3D printing processes, enhancing efficiency, reducing costs, and improving precision across industrial applications.Tailored for 3DCerams Ceramaker range, CERIA is built to meet the rigorous requirements of industries like aerospace, defense, and semiconductors, which demand high-resolution ceramic parts that maintain integrity at a large scale, challenges that CERIA is designed to overcome.Visitors at Formnext tradeshow this week can explore CERIAs capabilities at 3DCerams booth in Hall 11.1 D21. The demonstration will highlight CERIAs potential to reshape ceramic additive manufacturing for high-performance, technical applications.3DCerams C1000 FLEXMATIC. Photo via 3DCeram.Modular AI system to streamline productionStructured around two core AI modules, CERIA provides a comprehensive solution to streamline the entire 3D printing workflow. CERIA Set customizes printing parameters for each project, analyzing part designs and generating configurations that maximize productivity and precision.Meanwhile, CERIA Live delivers real-time monitoring and adjustments, maintaining an uninterrupted production flow. Together, these modules harness the benefits of stereolithography, enabling large-scale, automated production that suits the industrial scale and intricate demands of technical ceramics.CERIAs color-coded visualization optimizes part placement and detects slurry issues in 3D printing. Image via 3DCeram.According to the company, CERIA also integrates seamlessly with 3DCerams existing tools, Build-It and CPS 2.0, forming a complete ecosystem for managing every stage of ceramic 3D printing. CERIA Set provides targeted support from conception to production, guiding users in optimizing part placement and tank layout, and generating custom scraping parameters that meet exacting standards.By including a color-coded visualization system, CERIA Live enables real-time monitoring of each layer during the print process. Each color serves a purpose: white highlights the part being printed, yellow signals fixed slurry zones, and red marks potential slurry leaks, helping users identify and address issues quickly to ensure production success.Versatile applications across technical ceramics manufacturingCompatible with high-precision models like the C101 EASY FAB, C1000 FLEXMATIC, and C3601 ULTIMATE, CERIAs adaptability extends to a wide range of technical ceramics applications.3DCerams C1000 FLEXMATIC enables immediate reuse of recycled formulations, streamlining the next production cycle. Photo via 3DCeram.This versatility allows manufacturers to minimize material waste, reduce time to market, and achieve consistent, high-quality results. Efficiency is particularly crucial for technical ceramics, where streamlined production can make or break the ability to meet tight deadlines in industries like aerospace and semiconductors. A large build platform enhances this by allowing large parts to be printed as a single piece.With over 20 years of experience in ceramic 3D printing, CERIA underscores 3DCerams focus on refining AM for complex applications. Equipped with AI-driven design guidance, an emphasis on material efficiency, and real-time monitoring, CERIA provides a scalable solution aimed at enhancing the capabilities of ceramic 3D printing.As manufacturers look for dependable and cost-effective production methods, CERIA aims to contribute to the broader adoption of ceramic 3D printing across various industries.Catch up on all the news from Formnext 2024.Voting is now open for the 2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows CERIAs color-coded visualization optimizes part placement and detects slurry issues in 3D printing. Image via 3DCeram.

TRUMPF, a German leader in machine tools and laser technology, is set to debut its enhanced TruPrint 3000 3D printer at Formnext 2024, the international exhibition dedicated to additive manufacturing, scheduled for November 19 to 22. The enhanced system incorporates new dual 700-watt fiber lasers and an advanced cooling system. It is engineered to meet the high-output demands of sectors such as automotive and aerospace that require durable, precision-manufactured components.The upgraded TruPrint 3000 is equipped with Automatic Multilaser Alignment (AMA), which keeps the power of its dual 700-watt lasers stable, a necessary feature for producing consistent, high-quality parts. An integrated cooling system provides precise temperature control within the build platform, allowing full laser capacity operation without risking material degradation from overheating. This thermal stability is particularly significant for working with heat-sensitive metals, such as aluminum alloys, that can experience reduced strength under uncontrolled temperature fluctuations. Roland Spiegelhalder, Product Manager for Additive Manufacturing at TRUMPF, explained, The TruPrint 3000 is engineered for volume production of high-quality parts, serving industries with stringent durability standards.TruPrint 3000 with dual 700-watt lasers for high-precision 3D printing. Photo via TRUMPF.The cooling integration also enhances solidification rates, enabling parts with better durability and repeatabilitytwo factors critical to applications like crash-resistant automotive components, which require uncompromised material integrity. The enhanced system reduces the need for manual adjustments, supporting consistency across production runs and addressing high-throughput manufacturing needs.TRUMPFs engineers also increased the laser spot size from 80 to 200 micrometers, optimizing the systems speed by allowing it to cover a larger area on the build plate without sacrificing precision. This adjustment enables faster production cycles while maintaining part quality, ensuring the TruPrint 3000 meets the efficiency requirements of high-volume applications in industries with stringent quality standards.TruPrint 3000s laser bed in action, manufacturing metal parts. Photo via TRUMPF.The Future of Additive Manufacturing at Formnext 2024Formnext 2024 will feature around 860 exhibitors showcasing additive manufacturing advancements. In a recent interview with Mesago, the event organizers discussed strategies to maximize the event experience and highlighted industry perspectives on additive manufacturings trajectory. Despite global economic pressures, the sector remains optimistic, with many companies projecting growth in both domestic and international markets.Central themes for this years event include the adoption of high-performance polymers and metal alloys, advances in sustainable manufacturing practices, and the increasing role of artificial intelligence in streamlining production processes and improving quality control.Another major exhibitor, 3D Systems, will launch a range of new 3D printing technologies and materials at Formnext 2024. The company will introduce the PSLA 270, a high-speed SLA system designed for industrial workflows, alongside post-processing solutions like the Wash 400/Wash 400F and Cure 400. These systems aim to streamline operations in regulated industries such as energy and healthcare by automating resin cleaning and enhancing UV curing processes.The company will also present advanced materials, including Figure 4 Rigid Composite White and Accura AMX Rigid Composite White, which are engineered for applications requiring high stiffness and durability, such as wind tunnel testing and tooling. The companys selective laser sintering (SLS) and multi-jet printing (MJP) material portfolios will be expanded, alongside the Delfin INVAC 3D powder management system for metal 3D printing.3D Systems PSLA 270 solution accelerates time to part for production applications. Image via 3D Systems.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured Image showcases the TruPrint 3000 with dual 700-watt lasers for high-precision 3D printing. Photo via TRUMPF.

Berlin-based 3D printer manufacturer Xolo will introduce its new volumetric bioprinter, Xell, at Formnext 2024.This new production platform adds to Xolos growing volumetric 3D printer portfolio and seeks to make volumetric bioprinting more accessible to researchers. Xell is advertised as combining advanced 3D printing capabilities with an affordable price point, unlocking access to novel bioprinting capabilities without restrictive upfront costs.With prices starting at 20,000, a 50% academic discount is available until December 31st, 2024, lowering the price to just 10,000. According to Xolo, this makes Xell the most affordable advanced bioprinter on the market.Xolos new offering will be unveiled for the first time at Formnext 2024 in Frankfurt, from November 19 22. The new Xell 3D bioprinter can be found at the Xolo booth in hall 11.1, booth D31.Read all the news from Formnext 2024.Xell, Xolos new volumetric 3D bioprinter. Image via Xolo.Introducing Xell: affordable volumetric bioprintingXolos Xolography volumetric 3D printing technology was first introduced in 2020 through its Xube 3D printer. This was followed earlier this year with the companys Xube volumetric 3D printer, designed to support academic and industrial researcher applications within the bioprinting, MedTech, optics, and dental sectors.Building on these developments, the companys new Xell platform seeks to increase accessibility to volumetric bioprinting applications. Its build chamber is optimized for integration with Xolos sealed, disposable cuvettes. These ensure a controlled production environment, essential for protecting the integrity of sensitive bio-inks.The 10 x 17 x 10 mm build volume is reportedly ideal for processing high-value bio-inks. This size supports applications ranging from 3D printed tissue scaffolds to custom hydrogels.Xells small footprint allows it to fit into virtually any research-based workspace, further lowering the barrier to entry for researchers. Boasting full HD resolution and a high-intensity LED light sheet, Xell reportedly offers high-precision functionality for bioprinting complex structures with smooth surfaces. Its layer-free Xologrophy 3D printing capabilities guarantee isotropic properties. As such, Xolos Xell is optimized for those wanting to create advanced biomaterials.The Xell 3D printer is compatible with Xolos existing portfolio of ready-to-use bio-inks and offers plug-and-play functionality for immediate use, while Its user-friendly, intuitive interface is designed to reduce setup time. Additionally, the new bioprinter is an open platform, allowing researchers to develop and 3D print their own materials.As a compact, easy-to-use, and affordable bioprinter, Xell is targeted to labs wanting to quickly explore the potential of bioprinting. It allows researchers to conduct proof of concept studies without contending with substantial upfront costs. According to Xolo, researchers can first adopt Xell, before scaling up to more the advanced volumetric Xube 3D printer.Xolos Xube (left) and Xell volumetric bioprinters. Image via Xolo.Technical specification of the Xell 3D bioprinter3D print speedUp to 3 mm/minFeature size10 mBuild volume10 x 17 x 10 mmLight sheet385 nm or 405nmProjectorFull HDResin systemDisposable, sealed cuvettesConnectivityWifi, Ethernet, USB3D printer dimensions285 x 420 x 275 mmCertificationCEAll the news from Formnext 2024.Who are the leaders in additive manufacturing? Vote now in the 2024 3D Printing Industry Awards!Want to share insights on key industry trends and the future 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What does the future of 3D printing hold?What near-term 3D printing trends have been highlighted by industry experts?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on Twitter, like our Facebook page, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows Xell, Xolos new volumetric 3D bioprinter. Image via Xolo.

Two-photon polymerisation (2PP) 3D printing company UpNano GmbH has unveiled the NanoOne Green, a new high-resolution 3D printer set to be debuted at Formnext 2024.Adding to the companys NanoOne series, the system features a 515 nm wavelength green laser with a power of 400 nm and targets research and industrial applications.The NanoOne Green reportedly delivers 30% higher resolution than competing 2PP 3D printers, which generally operate at 780 nm. Capable of achieving detail elements below 100 nm in width, UpNano claims its new product unlocks new levels of detail for additive manufacturing.Offering broad material compatibility, the new 3D printer can process transparent, biocompatible, non-fluorescent materials well suited to optics and microfluidics applications. Thanks to its green laser, the system can use existing photochemistries, while also supporting the development of novel materials incompatible with standard 780 nm Lasers.With the NanoOne green, we have extended our NanoOne product line with a tool that delivers ultra-high-resolution features and paves the way for diverse industrial applications, commented UpNano CEO Bernhard Kenburg.UpNano is yet to reveal the price of its NanoOne Green system. The company will showcase the new high-resolution 3D printer next week during Formnext 2024. Visitors can find the company in hall 11.1, booth E40.Read all the news from Formnext 2024.UpNanos new NanoOne Green 3D printer. Image via UpNano.The new NanoOne Green enhances 2PP 3D printingUpNanos new NanoOne Green adds to the companys NanoOne 2PP 3D printer series, which features the NanoOne 1000 and NanoOne 250 systems.These 2PP 3D printers incorporate UpNanos patented adaptive resolution technology. This can dynamically expand the width of the laser beam by up to ten times to accelerate 3D printing in bulk material areas and shrink the beam where more precision is required. According to UpNano, adaptive resolution makes the NanoOne range the highest performing and most adaptable 2PP 3D printers on the market.As with its predecessors, the NanoOne Green is a compact desktop 3D printer, able to fit into most work environments. It features high-performance vibration isolation and a built-in clean room with a HEPA filter.The NanoOne Green comes delivered in a ready-to-use standard configuration. However, users can customize their system with NanoOne accessories to suit specific 3D printing requirements. These include fiber holders, wafer chucks, heatable materials vats, and stage inserts for biological substrates. All upgrades can be retrofitted, allowing NanoOne systems to evolve with changing industry demands.With its new 3D printer, UpNano is targeting a wide range of applications ranging from batch production of end-use parts to bioprinting in native cell environments. This flexibility is supported by the companys broad materials portfolio, which features fully biocompatible and fused silica formulations.NanoOne Green Accessories. Image via UpNano.Technical specifications of the NanoOne GreenSystem typeDesktop multiphoton laser lithography system3D printing processLayer-by-layer 2-photon polymerizationLight sourceFemtosecond fiber laserLaser wavelength515 nmLaser power400 mWScannerGalvanometer scannerStageLong-range piezo stageMaximum travel rangeUp to 120 x 100 x 49 mmStage address grid10 nmSystem dimensions58.5 x 71.0 x 65.0 cmTotal weight124 kgAll the news from Formnext 2024.Who are the leaders in additive manufacturing? Vote now in the 2024 3D Printing Industry Awards!Want to share insights on key industry trends and the future 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What does the future of 3D printing hold?What near-term 3D printing trends have been highlighted by industry experts?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on Twitter, like our Facebook page, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows UpNanos new NanoOne Green 3D printer. Image via UpNano.

Researchers at the SEAM Research Center have introduced new applications for Screw Extrusion Additive Manufacturing (SEAM), focusing on its use in construction.At the heart of this development is the Epic3D portal printer, a system capable of producing large-format plastic components for applications such as facade elements, fences, and gates. Using a continuous deposition process and stiffening structures, this technology delivers durable, weather-resistant components tailored for outdoor construction applications.Working with Wirth & Co. GmbH, Fraunhofer Institute for Machine Tools and Forming Technology (IWU) is using this approach to produce large-scale facade elements that meet fire safety, UV, and weather resistance standards. According to the team, SEAM technology addresses longstanding challenges in additive manufacturing, including the constraints of small build platforms and reliance on slow, expensive filament-based processes. By adopting granulate as the printing material, SEAM enables faster, more cost-effective production of customized components.Fraunhofer IWU plans to present its latest developments in SEAM technology at the Formnext 2024 trade show. Led by Dr. Martin Kausch Head of the Department of Sustainable Fiber-Plastic Composites, the research team will showcase their work at Hall 11.0, Stand E38, and Hall 11.0, Stand C29, in collaboration with Metrom.Attendees will have the opportunity to explore how granulate-based 3D printing is being applied to construction, including facade manufacturing, and its potential to reshape the industry.Dr. Kausch said, We make sophisticated design affordable. The personal touch in facade design is, of course, also achievable in traditional manufacturing. But only with processes like SEAM is it cost-effective.The new portal printer Epic3D enables the additive manufacturing of large-size components. Photo via Fraunhofer IWU.Customization and versatility in SEAM technologyCustomization is a significant advantage of SEAM, particularly for creating facade elements with intricate textures or unique shapes, such as company logos. This process uses a modified extrusion screw to melt and deposit granulate layer by layer onto the build platform.Unlike traditional methods such as fiber lamination and forming processes, SEAM eliminates the need for molds, reducing costs and production time. The ability to use pre-colored materials also removes the need for additional coating steps, streamlining the overall process.Three systems developed through collaboration with Metrom and 1A Technologies expand SEAMs application potential. These include Epic3D, METROM P1410, and SEAMHex. Among them, Epic3D stands out for its capability to handle large-format production, supported by a build platform measuring 2 meters by 1.7 meters. Complementing this, METROM P1410 brings additional versatility by integrating processing steps such as milling, expanding its application potential.Lastly, SEAMHex employs a unique six-axis parallel kinematics system that provides high dynamics and movement flexibility, ensuring exceptional positioning and path accuracy. This design ensures exceptional positioning and path accuracy while reducing moving mass, resulting in reliable and efficient production of medium-sized components. Together, these systems cater to a broad range of manufacturing needs with precision and adaptability.Florian Stckel, managing director of Wirth & Co. GmbH, underlined the importance of the collaboration with Fraunhofer IWU in enhancing the SEAM process for construction applications. He explained that the Epic3D portal printer plays a crucial role in enabling new design possibilities for facade construction.Stckel noted that the partnership focuses on optimizing various aspects, including design, materials, and the 3D printing process itself. He also highlighted that the companys investment in the Epic3D system represents a step toward making additive manufacturing more suitable for producing building components.The SEAM Research Center: Epic3D (bottom left), METROM P1410 (center), and SEAMHex. Photo via Fraunhofer IWU.Broadening the frontiers of construction researchBeyond SEAM, other research highlights the evolving landscape of additive manufacturing in construction. One notable example includes Massachusetts Institute of Technology (MIT) and Evenline researchers who studied the feasibility of using glass 3D printing to create interlocking masonry units. Published in Springer Nature, this research highlights how glass AM can enhance design flexibility and reduce tooling costs compared to traditional methods.Using the G3DP3 printer, the team developed modular masonry units tested across three fabrication methods: Fully Hollow, Print-Cast, and Fully Printed. Findings revealed varying strengths and surface accuracies, with Fully Hollow units showing the highest structural performance. As per the team, this study emphasizes glass AMs potential for recyclable, sustainable construction, though further refinement is needed for large-scale applications.Elsewhere, University of Virginia (UVA) researchers developed a sustainable cementitious composite for 3D printing by incorporating graphene nanoplatelets (GNPs) into limestone-calcined clay (LC2). Led by Professor Osman Ozbulut, this research enhances structural integrity and environmental performance, increasing compressive strength by 23% with just 0.05% GNPs while improving printability.A Life Cycle Assessment revealed a 31% reduction in greenhouse gas emissions compared to traditional cement-based mixtures. Conducted with the Virginia Transportation Research Council, the study positions graphene-enhanced LC2 as a promising material for sustainable construction, particularly in transportation infrastructure.Catch up on all the news fromFormnext 2024.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the SEAM Research Center: Epic3D (bottom left), METROM P1410 (center), and SEAMHex. Photo via Fraunhofer IWU.

Ohio-based chemicals and materials company Lubrizol has teamed up with Lore Cycle to 3D print personalized cycling shoes.Avid Product Development, Lubrizols 3D printing division, uses 3D scans of the riders feet to fabricate footwear that perfectly fits each customers unique foot shape. The result is the Lore Twoa cycling shoe featuring a 3D-printed thermoplastic polyurethane (TPU) upper, aimed at delivering unparalleled comfort and support.The Lore Two collection offers three models to suit various cycling preferences. The Lore Two Low Nylon, starting at $1,349, is engineered to deliver a superior pedaling experience compared to standard cycling shoes.The next model, the Lore Two Low Carbon, is priced at $1,649 and is both lighter and more rigid than the Low Nylon version. It is designed for riders who prefer a traditional dorsal cut with no upper dorsal contact, providing greater responsiveness.At the top of the line is the Lore Two Mid Carbon, a premium option costing $1,849. This incorporates patent-pending, lightweight carbon dorsal upper panels to amplify power and performance.By harnessing the power of Lubrizol solutions, Lore Cycle is revolutionizing how shoes are manufactured and worn, commented Gert-Jan Nijhuis, General Manager of Lubrizol 3D Printing. We are thrilled to see how our technology has contributed to the creation of Lores 3D printed shoes, which combine cutting-edge technology with Lubrizols material & application science.Nijhuis further emphasized the benefits of additive manufacturing. He noted that it enables more sustainable onshore production and offers customers the opportunity to personalize their sportswear for enhanced comfort and performance.Lead times for the new Lore Two cycling shoes are currently estimated at 12 to 14 weeks.Lore Two 3D printed shoe. Image via Lore Cycle.The Lore Two: personalized, 3D printed cycling shoesStephan Drake, Lore Cycles CEO, calls the Lore Two a groundbreaking leap forward into the future of footwear.Conventional cycling shoes are generally built from mass-produced, generic molds or lasts. These tend to reflect an average foot shape, without accounting for individual variations in foot width, arch height, toe shape, or biomechanics.By contrast, the Lore Two 3D printed shoes are custom-made and designed to perfectly match the unique shape of each riders feet. This personalized approach aims to improve fit, comfort, and performance. The shape of the carbon shell accurately cups your sole, relieves fat pad pressure, and features a perfected custom toe box that lets your foot spread out under load, explained Drake. This reportedly translates to enhanced power transfer and pedal efficiency, reduction of traditional dead spots, and better aerodynamics.Because the Lore Two shoes are fully customized, the buying experience is also unique. To purchase a pair of custom 3D-printed cycling shoes, customers first need to provide a high-resolution 3D scan of their feet, which takes about 10 minutes to complete. This scan can be done at select bike shops across North America, Europe, Asia, and Australia. For customers who arent near a participating location, Lore Cycle offers to ship a 3D scanner to the nearest bike shop to facilitate the process.Next, each unique 3D scan is converted into a bespoke cycling shoe design, which is then 3D printed using Lubrizols additive manufacturing materials. The final product assembly is performed by a third party, with Lubrizols materials and 3D printing technology only used for the shoe upper.Once produced, the cycling shoes are shipped directly to the customer.Lubrizol Advance Materials headquarters building in Brecksville, Ohio. Photo via Lubrizol.3D printed shoes hit the shelves3D printing has received growing interest within the footwear market, thanks to its ability to personalize products for unique customer needs. Last year, multinational printing firm HP partnered with Brooks Running to develop Exhilarate-BL 3D printed running shoes.These shoes feature 3DNA, a 3D printed midsole technology that provides a propulsive, springy feel. Running data from customers is used to tailor the midsole size, enhancing cushioning and bounce. Multi Jet Fusion (MJF) 3D printing technology was used to fabricate the shoe midsoles, which reportedly outperforms 90% of competitors in todays market.Elsewhere, 3D printing has been adopted to enable more flexible and affordable shoe production. Earlier this year, it was announced that 3D printed footwear startup ELASTIUM had partnered with LaLaLand Production & Design, Californias largest shoe manufacturer.This collaboration seeks to accelerate localized and sustainable mass production through the No-Minimum-and-Maximum-Order-Quantity (No-MMOQ) approach. Here, 3D printing is combined with conventional mass manufacturing techniques, reportedly cutting investment costs by up to 80%. It offers brands the ability to go from concept to market in a matter of weeks without minimum or maximum order quantities.The first product launched through this partnership was the Orca, Elastiums latest 3D printed sneaker. This combines a TPU foam 3D printed midsole with a combined elastane and 3D printed TPU upper.All the news from Formnext 2024.Who are the leaders in additive manufacturing? Vote now in the 2024 3D Printing Industry Awards!Want to share insights on key industry trends and the future 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What does the future of 3D printing hold?What near-term 3D printing trends have been highlighted by industry experts?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on Twitter, like our Facebook page, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows a Lore Two 3D printed shoe. Image via Lore Cycle.

Austrian engineering firm and OEM Incus GmbH has introduced the Hammer Evo35, a redesign of its Hammer Lab35 Lithography-based Metal Manufacturing (LMM) 3D printer.Set to be unveiled for the first time next week during Formnext 2024, the system has been updated to offer improved production capabilities and industrial performance for professional applications. Its compact footprint makes it ideal for manufacturing environments with limited space, allowing it to integrate into most industrial workflows.The Evo35 features key upgrades that differentiate the system from its predecessor. This includes an overhaul of the 3D printer architecture and projector unit, an updated climate control system, and new software capabilities.According to Incus, this redesign and name change reflects the companys commitment to innovation and adaptability in the rapidly evolving world of additive manufacturing.We are proud to introduce the Hammer Evo35, a reflection of our ongoing dedication to advancing metal additive manufacturing, commented Incus CEO, Dr. Gerald Mitteramskogler.He added that the redesign combines the advantages of the companys LMM technology with new features that increase efficiency, reduce costs, and improve safety, while maintaining the superior quality our customers expect.Visitors to Formnext 2024 will be able to view the Hammer Evo35 3D printer at the Incus booth, located in Hall 11.1, E59.Read all the news from Formnext 2024.The Hammer Evo35 3D printer. Image via Incus.Introducing the Hammer Evo35 LMM 3D printerIncus was founded in 2019 in the R&D lab of ceramic 3D printing specialist Lithoz, a spin-out of TU Wein. Its LMM technology is based on vat polymerization techniques such as stereolithography (SLA) and Digital Light Processing (DLP). However, it differs from these more conventional technologies by processing materials that contain metal particles. The 3D printed parts are debound and sintered to create solid metal parts, similar to metal binder jetting and FDM techniques that use metal-infused filament.Incus technology can process materials containing metal particles as small as 20 m in size and is compatible with unweldable metals. LMM reportedly improves production health and safety by avoiding airborne powders, heightens production accuracy, and offers faster 3D printing speeds.The companys newly updated Hammer Evo35 3D printer is designed for production applications beyond research and development. It features a new CNC-grade machine frame, mechanics and the latest generation of projector units. This overhaul of the 3D printers architecture reportedly guarantees industrial standards in usability and durability.According to Incus, the new projector system further enhances the benefits offered by LMM technology. It optimizes metal 3D printing resolution and surface finish and unlocks a larger build area.The upgraded Evo35 also boasts an improved climate control system for the build chamber, guaranteeing part quality and ensuring 3D print jobs are successful in all production environments. A new software architecture has also been integrated into the 3D printer. This industrial interface reportedly streamlines communication with enterprise resource planning (ERP) systems, further enhancing the additive manufacturing experience.Incus LMM 3D printed part. Photo via Incus.New resin 3D printers at Formnext 2024With around 860 exhibitors and 55,000 square metres of exhibition space, Formnext 2024, running from 19-22 November in Frankfurt, is set to feature a plethora of new 3D printer launches. Among these, several new stereolithography-based systems will be unveiled on the show floor.During the event, 3D Systems will introduce its new high-speed PSLA 270 SLA 3D printer, along with Wash 400/Wash 400F and Cure 400 post-processing units. The new industrial resin 3D printer reportedly combines the speed and precision of projector-based SLA technology to fabricate mid-sized, high-quality parts with consistent mechanical properties. Compatible with this new 3D printer, 3D Systems new Figure 4 Rigid Composite White and Accura AMX Rigid Composite White materials are optimized for applications like wind tunnel testing, tools, and fixtures.Also exhibiting at Formnext 2024 is the industrial 3D printing company Supernova. During the show, Supernova will be showcasing its new Pulse Production Platform for high-viscosity resin 3D printing. It will also debut its Viscogels portfolio photopolymer materials that match the properties of injection molding.Supernova claims its new products will reduce tooling costs, improve customization capabilities, and enhance 3D printing productivity for batch production of end-use parts. According to CEO Roger Antunez, the new offerings seek to stem the unrivalled market growth of low-cost, Chinese-made 3D printers from companies like Creality and Bambu Lab. He believes Supernovas materials first approach will increase the adoption of Viscous Lithography Manufacturing (VLM) technology.Keep up to date with all the news from Formnext 2024.Who are the leaders in additive manufacturing? Vote now in the 2024 3D Printing Industry Awards!Want to share insights on key industry trends and the future 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What does the future of 3D printing hold?What near-term 3D printing trends have been highlighted by industry experts?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on Twitter, like our Facebook page, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows the Hammer Evo35 3D printer. Image via Incus.

3D printer manufacturer Roboze has introduced SlizeR, a new proprietary slicing software tailored to improve efficiency and performance in additive manufacturing.Developed as part of Robozes broader strategy to elevate production quality and operational efficiency, SlizeR is promoted under the slogan Your Production Power, emphasizing its role in boosting competitiveness by optimizing production and reducing setup times.Scheduled for its official unveiling at the Formnext 2024 tradeshow next week, SlizeR will be showcased at Robozes booth (hall 11.1, D12). Attendees will have the opportunity to explore its capabilities and discover how it enhances Roboze technologies, as the company reaffirms its role as a strategic partner for businesses transitioning to more efficient, sustainable, and customized manufacturing solutions.SlizeR is designed to optimize your production process and ensure high-quality parts. Image via Roboze.Streamlines workflow and enhances print qualitySlizeR offers an array of features aimed at advancing additive manufacturing workflows. By significantly reducing transition time from 3D models to R-code (G-code), SlizeR enables a faster, more streamlined process, cutting down time-to-market and enhancing workflow efficiency. Optimized print parameter management combined with automated settings contributes to system repeatability, ensuring consistent quality across production runs and improving reliability.A data-driven approach underpins SlizeRs automatic adjustments to print parameters, facilitating dimensional consistency that aligns the final product closely with its original design. These automated settings make SlizeR user-friendly, supporting those who lack extensive additive manufacturing expertise. Enhanced print trajectories also contribute to part quality, minimizing internal defects and increasing mechanical performance.Material control is another focal point in SlizeRs design, providing accurate management of resources that help reduce waste and forecast material needs for each project. Designed with a user-friendly interface, SlizeRs intuitive layout ensures users can navigate the process with ease, regardless of experience level, promoting smooth management at every stage.Built to evolve with Robozes ongoing developments, SlizeR adapts to new materials and machine functionalities, consistently unlocking productivity potential across Robozes additive manufacturing solutions. This adaptability, coupled with features that simplify complex projects and enhance production flexibility, positions SlizeR as a valuable tool for companies seeking professional-grade results without requiring in-depth expertise.Roboze SlizeR software logo. Image via Roboze.Digital manufacturing software drives efficiency and scalabilityDigital manufacturing software streamlines production by optimizing processes, reducing errors, and lowering costs, making high-quality manufacturing more accessible. It also enables scalability, allowing manufacturers to quickly adapt to changing demands and maintain competitiveness. In line with this, manufacturing technology company Hexagon introduced Digital Factory, a digital manufacturing solution from its Manufacturing Intelligence division aimed at enhancing productivity in factory operations.Debuted at the Farnborough International Air Show 2024, Digital Factory allows companies to create detailed digital replicas of their facilities, including digital twins of machine hardware, enabling optimized layouts and adaptive production management. Projected to save companies 35 million annually, Digital Factory minimizes planning errors and cuts travel costs. With seamless integration into BIM applications and Hexagons cloud-based tools, it supports remote monitoring and efficient collaboration, advancing smarter and more sustainable manufacturing environments.Additionally, additive contract manufacturer Endeavor 3D partnered with HP and Materialise to implement the Materialise CO-AM software, a streamlined digital manufacturing workflow solution designed to expand production capacity and optimize workflows across its HP 3D printers.By adopting this digital approach, Endeavor 3D can address the rising demand for industrial 3D printed applications while moving away from traditional, manual methods like emails and spreadsheets. CO-AMs Order Management System efficiently organizes incoming requests, complemented by automatic notifications and real-time sensor data for quality control. Features like the Magics Nester module further enhances production efficiency, supporting Endeavor 3Ds goals of increasing labor productivity and improving yield.Catch up on all the news fromFormnext 2024.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the SlizeR interface, designed to optimize your production process and ensure high-quality parts. Image via Roboze.

3D printing service bureaus Forecast 3D, FKM, Hasenauer & Hesser, and RapidCenter have integrated DyeMansions Powerfuse S vapor smoothing technology into their operations, signalling a shift across the 3D printing industry toward environmentally friendly practices.By moving away from traditional PFAS-based solvents in favor of green alternatives, these companies are aligning high-quality production standards with an increasing emphasis on environmental responsibility. Describing Powerfuse S as a scalable, eco-friendly solution, RapidCenters Managing Director, Floris Stam, highlighted how the technology aligns with their goals for innovation and sustainability.Compared to conventional solvents, green alternatives reduce both safety infrastructure needs and regulatory burdens, streamlining operations while lowering emissions and the costs associated with specialized extraction systems. This shift brings both logistical and environmental advantages.DyeMansions Powerfuse S post-processing system. Image via DyeMansion.A shift toward sustainable vapor smoothingIntroduced by DyeMansion in 2019, Powerfuse S marked a major development in vapor smoothing by adopting a closed-loop system that recycles green solvents, curbing environmental impact and operational expenses.Previous vapor smoothing processes often relied on open solvent baths, later transitioning to closed systems that used HFIP, a PFAS forever chemical known for its persistence in the environment. With over 50 units now in use across the industry, DyeMansion has emerged as a leader in steering vapor smoothing technology toward sustainable solutions.By providing precision smoothing for intricate geometries, Powerfuse S allows 3D printing service providers to achieve consistent quality and meet specific certifications, including FDAs 21 CFR and EUs 10/2011 standards for food safety. This capability facilitates entry into regulated markets, expanding application possibilities for 3D printed products.Recently, Forecast 3D joined DyeMansions Production Partner network, incorporating Powerfuse S to enhance its range of services. Alongside companies such as Endeavor 3D, SNL Creative, Solaxis, and Prototal, Forecast 3Ds partnership with DyeMansion grants access to the comprehensive Print-to-Product workflow.Endeavor 3Ds CEO, Phil Arnold, emphasized that early adoption of DyeMansions green technology has aligned with their goals for lean and responsible production, benefiting their clients over the past three years.As more companies adopt green solvents, the 3D printing industry is steadily shifting toward sustainable manufacturing practices, with companies moving away from PFAS chemicals in favor of greener alternatives. This transition reflects a broader industry trend toward environmentally conscious production methods in industrial applications.Novel post-processing solutionsWhile DyeMansions Powerfuse S addresses sustainable vapor smoothing, other companies are advancing post-processing technologies across a range of applications.For example, Swedish post-processing solutions provider AM Efficiency recently launched UNPIT, an automated post-processing machine for entry-level Selective Laser Sintering (SLS) 3D printers, which will debut at Formnext 2024.Designed for SMEs, UNPIT handles unpacking, de-powdering, cleaning, and material recovery, reclaiming up to 100% of unused powder to reduce waste and operational costs. Adaptable with Selective Laser Sintering (SLS) brands like Formlabs and Sinterit, the machine integrates seamlessly into workflows, automating processes that traditionally require manual labor. Developed in partnership with Siemens, UNPIT shipments are set to start in early 2025, aiming to enhance efficiency for SLS users.Austrian 3D printing firm M&H incorporated Solukons SFM-AT1000-S depowdering system to enhance post-processing of complex metal parts. This advanced system removes powder residues from intricate internal channels and heavy components up to 1,000 mm in height and 800 kg in weight.Equipped with servo-driven rotating axes and a high-frequency knocker, it ensures thorough cleaning while meeting safety standards for reactive materials. M&Hs integration aims to meet the rigorous demands of industries like aerospace and international racing, positioning the company for large-scale manufacturing.Catch up on all the news fromFormnext 2024.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows DyeMansions Powerfuse S post-processing system. Image via DyeMansion.

Supernova, a carve-out of Spanish 3D printer manufacturer BCN3D, has launched its new Pulse Production Platform for high-viscosity resins. The company has also unveiled Viscogels, a proprietary portfolio of photopolymer materials offering superior mechanical properties to competing resins.The new platform features the Pulse One Viscous Lithography Manufacturing (VLM) 3D printer, Pulse Postprocessing Cell, and Pulse Control Center software. This end-to-end manufacturing suite is compatible with the companys Viscogels lineup, which features twelve different materials spanning four photopolymer families (rigid composites, ductile materials, rubber, and silicone).Supernova claims its new products will reduce tooling costs, improve customization capabilities, and enhance 3D printing productivity for batch production of end-use parts. Additionally, Viscogels reportedly reduce emissions of toxic volatile organic compounds (VOC) during 3D printing, addressing a growing challenge in the resin 3D printing market.During the online launch event, Supernovas CEO Roger Antunez outlined the companys efforts to counter the growing market share of emergent Chinese 3D printer manufacturers. According to CONTEXTs latest 3D printing market figures, professional users are increasingly adopting low-cost, Chinese-made 3D printers from the likes of Creality and Bambu Lab. The latter registered 336% YoY shipment growth in Q2 2024.Antunez shared his concerns that most Western additive manufacturing companies have cut back on R&D investment, while real breakthroughs often come from China. He added that Western companies are being wiped out by these Chinese new players which offer better technology and extremely low prices.To combat this, Supernova is bolstering its R&D initiatives and developing viscous materials that match the properties of conventional injection molding. Antunez believes this materials first approach will accelerate the adoption of its VLM additive manufacturing technology, unlocking industrial-grade parts at low costs.We are on a mission: to make impossible plastic molding runs possible, added Antunez. We are breaking through barriers to enable customers to produce industrial-grade components with advanced properties, while remaining cost-efficient regardless of production volume.Viscogels and the Pulse Production Platform will begin shipping in Fall 2025. Supernova will showcase its new products next week at Formnext 2024 in hall 11.0, booth D62J.Supernovas new Pulse Production Platform and Viscogels. Image via Supernova.Viscogels: a new high-viscosity resin portfolio Supernova has classified its Viscogels into four material families.The Rigid Composites family is comparable to glass-filled PA6, ABS and Polymethyl methacrylate (PMMA). These materials are designed to provide strength, stiffness and dimensional stability.The Ductile family resembles polypropylene, PVC and PA11. These formulations reportedly offer high-impact resistance and elongation before breaking.The Rubber Viscogels family seeks to meet more flexible needs. They feature high tear strength and elasticity, matching the performance of EPDM, soft TPUs and TPEs.Finally, the Silicone family mirrors silicone rubbers. They offer resistance to temperatures ranging from minus 60 to over 200.Viscogel materials are highly viscous, with formulations starting at 20,000 cP and some reaching over 1 million cP. Conventional resin 3D printers, on the other hand, generally process photopolymer materials below 1000 cP.The high viscosity of Viscogels is achieved by formulating the materials with at least 80% oligomers, 4 times more than typical 3D printing resins. This reportedly allows the 3D printable materials to rival the tensile strength, impact resistance, and temperature resistance of molded plastics such asPA6, Polypropylene (PP), EPDM, and liquid silicone rubber.Thanks to their high viscosity, Viscogels can incorporate higher loadings of solid additives like ceramics and metals without compromising processability. They are also compatible with a wider variety of additive shapes, further enhancing the strength and durability of 3D printed parts.According to Robert Young, Supernovas Director of Materials, water absorption and chemical resistance are the biggest challenges that prevent the adoption of photopolymer additive manufacturing.Low-viscosity resins create a porous structure, allowing liquids and chemicals to be absorbed into the material, which damages the properties of 3D printed parts. The high oligomer content of Viscogels combats this, creating a denser polymer matrix which is less porous. For instance, Supernovas new materials exhibit a water absorption of less than 0.5%.Viscogels also significantly reduce emissions of VOCs, which are harmful to humans. The potential health effects of these chemicals range from headaches and nausea to kidney damage and cancer.In photopolymer 3D printing, VOC emissions are mainly caused by monomers within the resin material. Young explained that some monomers can become trapped in the polymer matrix during curing. These uncured monomers migrate to the surface of the 3D printed part and release into the air.Viscogels possess a lower monomer content compared to traditional low-viscosity photopolymers. This reportedly ensures that more monomers fully cure within the material, significantly reducing VOC emissions. Young added that this allows Viscogels to meet strict industry requirements, ensuring safer, cleaner and more sustainable end parts.Supernova Viscogels portfolio. Image via Supernova.Supernovas new end-to-end production platformDue to their extremely high viscosity, Viscogels can only be processed using Supernovas VLM technology. To 3D print these materials, Supernova has developed its Pulse Production Platform, incorporating a new 3D printer, post-processing unit, and software.The Pulse One VLM 3D printer features an XY resolution of 46m, a build volume of build volume of 350 x 200 x 300 mm, and a Z resolution range of 50 200m. It can reportedly achieve a throughput of 5 kg/hour, supporting batch production applications.The Pulse One is unique within the resin 3D printing space due to its dual-material 3D printing capabilities. It can simultaneously combine two materials in a single layer for multi-material parts, or 3D print a secondary support material. VLM is currently developing a fully water-soluble support material to automate the support removal process.Supernovas Pulse One 3D printer. Photo via Supernova.Supernovas Pulse Postprocessing Cell is an automated post-processing unit which washes and cures parts 3D printed on the Pulse One. It can reportedly process up to 24 builds per day and employs thermal and UV curing to achieve optimal mechanical properties. The cell boasts automated quality control at each step, ensuring all 3D printed batches are processed correctly. Additionally, RFID tracking ensures traceability throughout the workflow.This traceability and quality control, along with build preparation and slicing, is managed by the Pulse Control Center software. This platform reportedly ensures part repeatability by tracking the production process. Its algorithm can detect defects during the 3D printing process and automatically make corrections to maintain high production standards.Supernovas Pulse Processing Cell. Photo via Supernova.Developments in resin 3D printingSupernovas Viscogels are the latest 3D printing resins to enter the additive manufacturing market.Last month, 3D printing materials producer polySpectra launched Cyclic Olefin Resin (COR) Zero, its new manufacturing-grade resin that can be used with affordable 3D printers. The company claims that this material brings industrial-level production capabilities into home workshops and small businesses.COR Zero reportedly offers a cost-effective alternative to injection molding for makers, designers, and engineers. It is optimized for applications like mechanical components, fluidic parts, electronic enclosures, and wearables such as glasses and podiatry inserts. The resin also seeks to tackle common challenges relating to brittleness and thermal instability. Compatible with desktop DLP and LCD 3D printers, COR materials combine toughness, heat resistance, and chemical durability. Specifically, it boasts a tensile strength of 53 MPa, a modulus of 2175 MPa, and an elongation at a break of 18%.Elsewhere, Formlabs Dental, the dental business unit of Resin 3D printer manufacturer Formlabs, recently received510(k) clearance from the US Food and Drug Administration (FDA) for its Premium Teeth Resin. This allows dental professionals in the US to 3D print dental components, such as single units of crowns, inlays, onlays, veneers, and up to seven-unit temporary bridges, with the resin.Launched in January 2024, Premium Teeth Resin is a nano-ceramic-filled biocompatible material for realistic dental parts that mimic the translucency and opalescence of natural teeth. The resin is compatible with Form 3B+, Form 3BL, and Form 4B 3D printers, and has also been cleared for use in the EU, UK, Switzerland, and Canada.Read all the news from Formnext 2024. Who are the leaders in additive manufacturing? Vote now in the 2024 3D Printing Industry Awards!Want to share insights on key industry trends and the future 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What does the future of 3D printing hold? What near-term 3D printing trends have been highlighted by industry experts?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on Twitter, like our Facebook page, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows Supernovas Pulse One 3D printer. Photo via Supernova.

Caracol, a developer of large-format additive manufacturing (LFAM) technologies, is set to introduce its latest innovation, Vipra AM, at Formnext 2024. Designed to address the rising demand for efficient, large-scale metal 3D printing, Vipra AM integrates robotic deposition technology with automation to facilitate the production of complex industrial components. Caracol aims for Vipra to set a new benchmark in large-format metal manufacturing, responding to the manufacturing sectors need for adaptable and sustainable solutions.Vipra AM employs Direct Energy Deposition with wire arc additive manufacturing, expanding the potential of LFAM. This proprietary platform, engineered for flexibility and control, comes in two distinct configurations. Vipra XQ (Extreme Quality) applies Plasma Arc Deposition to achieve high precision and strength, making it suitable for structural components in aerospace and energy sectors. Vipra XP (Extreme Productivity), built to maximize throughput, supports lightweight metals like aluminum and nickel, ideal for industries where rapid production and weight efficiency are essential, such as automotive and marine.Caracol Launches Vipra AM. Photo via Caracol.Francesco De Stefano, Caracols CEO, explains, Our focus has been to combine application-driven approaches with advanced technologies that support the production of large-scale, complex parts. Caracols years of experience with polymer-based LFAM have culminated in Vipra AM, an integrated system that combines monitoring, automation, and material versatility.Engineered to complement existing manufacturing workflows, Vipra AM enables hybrid production models that incorporate traditional methods alongside advanced metal deposition. This approach aims to reduce material waste, shorten lead times, and increase operational efficiency without requiring complete retooling of production lines. Gianrocco Marinelli, Caracols Director of Metal Additive Manufacturing, notes Vipras role in addressing manufacturers challenges related to resource efficiency and operational speed, pointing to the platforms capacity to produce components like high-temperature autoclave molds and complex structural parts.Caracol plans a full showcase of Vipra AM at Formnext, with a live demonstration and panel discussion on November 19, 2024, at booth C101 in Hall 12.1. Industry experts will discuss the emerging synergies between polymer and metal LFAM, along with the platforms impact on future manufacturing paradigms. Caracol envisions Vipra AM not only enhancing efficiency but also redefining the possibilities of large-scale metal additive manufacturing.Caracols booth location at Formnext 2024. Image via Caracol.Large-Scale Additive ManufacturingIn other large-scale 3D printing news,Rocket Lab, a space launch company based in California, has deployed a 90-ton automated fiber placement (AFP) machine to construct large carbon composite rocket structures. This AFP system, built by Electroimpact, automates the production of major composite components for Rocket Labs Neutron launch vehicle, reducing production time from weeks to hours.Additionally, Rapid Fusion, a UK-based company in the additive manufacturing sector, has introduced its Apollo system, a large-format pellet-based 3D printing solution. The Apollo system utilizes robotics to produce large components and molds, targeting industries such as automotive and aerospace. Capable of handling high extrusion rates and a wide range of engineering-grade polymers, Apollo offers significant improvements in printing speed and material cost efficiency.Rocket Labs 90-tonne automated fiber placement (AFP) machine. Photo via Rocket Lab.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Feature image showcases the new Vipra AM to be unveiled at Formnext 2024. Photo via Caracol.

US-based 3D printer manufacturer 3D Systems will be launching a range of 3D printing technologies and materials at this years Formnext tradeshow.Aligned with scaling industrial 3D printing, key highlights include the high-speed PSLA 270 SLA system, purpose-built post-processing solutions like Wash 400/Wash 400F and Cure 400, and advanced materials such as Figure 4 Rigid Composite White and Accura AMX Rigid Composite White, all tailored to meet demanding industrial workflows.Recent expansions in Selective Laser Sintering (SLS) and MultiJet Printing (MJP) materials, as well as a new powder management system for the DMP Flex 200 metal 3D printer, will also be showcased to emphasize efficiency and reduced production times for industrial applications. Attendees can explore these new offerings at 3D Systems booth in Hall 11.1, Booth D11.Our customers ingenuity fuels our innovation, explained Marty Johnson, vice president of product and technical fellow, 3D Systems. By collaborating closely with their engineering teams, were pushing the boundaries of additive manufacturing. To keep pace with their evolving needs, were constantly expanding our solution portfolio. Our latest additions, new accessories and materials, are prime examples of how customer-centric innovation can deliver a competitive edge.3D Systems PSLA 270 solution accelerates time to part for production applications. Image via 3D Systems.Post-processing solutions and rigid materials for enhanced productionAccording to 3D Systems, the PSLA 270 combines the speed and precision of projector-based SLA technology to deliver mid-sized, high-quality parts with consistent mechanical properties, suited for industrial workflows.Supporting the PSLA 270s capabilities, the Wash 400 and Wash 400F systems automate resin cleaning with Dirty and Clean washing workflows that allow users to choose between non-flammable and flammable detergents, such as IPA. Featuring a piston lift, these solutions simplify part handling while streamlining industrial operations.Additionally, the Cure 400 enhances UV curing with programmable settings, a 400 x 400 x 400 mm curing volume, and a rotating table for optimal shadow reduction, allowing compatibility with all 3D Systems SLA and Figure 4 platforms. Availability for these post-processing solutions is anticipated in early 2025.Expanding options for high-stiffness materials, Figure 4 Rigid Composite White and Accura AMX Rigid Composite White support applications such as wind tunnel testing, tools, and fixtures. With enhanced resistance to settling, these materials help minimize maintenance and boost printer uptime, offering smooth workflows and high-quality surface finishes. Distribution across Europe is expected by December 2024, followed by a global rollout in 2025.Advanced thermal control and broadened SLS and MJP material portfoliosFor high-yield, consistent production, the SLS 380 introduces advanced thermal control, incorporating eight calibrated heaters and a high-resolution infrared camera sampling at 100,000 times per second.This setup supports precise chamber conditions, ensuring a consistent build environment and reliable part quality. Paired with the SLS 380 are new materials such as DuraForm PA12 Black, DuraForm TPU 90A, DuraForm PA CF, DuraForm FR 106, and DuraForm PA 11 in both natural and black variations, all of which will be available starting December 2024.With the ProJet MJP 2500 Plus, new material options like VisiJet Armor Max and VisiJet M2P-CST Crystal bring ABS-like durability and intricate casting ability for complex prototyping and jewelry applications. Moreover,VisiJet M2P-CST Crystal offers fine detail and strength suitable for jewelry with detailed features, including rings, bracelets, and brooches.ProJet MJP 2500 Plus. Image via 3D Systems.Further optimizing the production process, the Delfin INVAC 3D powder management system, developed for the DMP Flex 200, enables safe, closed-loop metal powder recovery, especially valuable for applications in dental labs.Conference program and presentationsThroughout Formnext 2024, 3D Systems will host several sessions showcasing these advancements. Scheduled for November 20, QuickCast Air Enabling the Next Step Change in 3D Printed Investment Casting Pattern Efficiency will run from 10:15 to 10:30 a.m. on the Technology Stage in Hall 12.0.Later that morning, from 11:30 to 11:50 a.m., Realizing the Benefits of Decentralized Manufacturing of Highly Regulated Parts in the Energy Industry will be presented on the Application Stage in Hall 11.1. In the afternoon, PSLA 270: The Speed of Light-projection. The Quality and Reliability of SLA. will be presented from 2:30 to 2:45 p.m. on the Technology Stage in Hall 12.0.The following day, November 21, Model No. Redefines Sustainable High-End Furniture with Additive Manufacturing will take place from 10:30 to 10:50 a.m. on the Application Stage in Hall 11.1.These sessions provide insights into 3D Systems newest solutions and their applications across industries, from investment casting and regulated manufacturing to sustainable furniture production.Scaling industrial 3D printing with new solutionsIn the broader landscape of industrial 3D printing, other companies are also expanding capabilities. Chinese metal 3D printer manufacturer Eplus3D recently contributed to improving industrial 3D printing by introducing the EP-M4750, a high-efficiency metal 3D printer designed for large-scale batch production in sectors like aerospace, automotive, and tooling.Utilizing Metal Powder Bed Fusion (MPBF) technology, the EP-M4750 features a 450 x 750 x 530 mm build chamber and up to four 500 W lasers for fast throughput. The system supports various metals and includes an optimized gas flow, multi-stage filtration, and adaptive software, enabling flexible, high-strength part production suited for demanding industrial applications.Last month, Lynxter introduced the S300X FIL11 | FIL11, an industrial IDEX 3D printer for high-speed, dual-material printing, ahead of Formnext 2024. Built to handle thermoplastics, it reaches 10,000 mm/s acceleration, 24 mm/s extrusion with dual extruders, and supports complex, high-strength parts.Features include a 500C nozzle, a heated chamber, and an integrated dehydration unit for optimal print quality. Designed with a health-conscious filtration system, the S300X targets sectors needing robust, quality parts and can be pre-ordered in Europe.Catch up on all the news fromFormnext 2024.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows 3D Systems PSLA 270 solution, which accelerates time to part for production applications. Image via 3D Systems.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

Semiconductor and fiber laser specialist nLight will launch its new Corona AFX-2000 two-kilowatt beam shaping laser at Formnext 2024. Designed to enhance laser powder bed fusion 3D printing, nLight claims that its new laser will significantly boost the productivity of metal additive manufacturing.Featuring dynamic laser beam shaping technology, the new AFX-2000 can reportedly deliver double the power of other lasers while maintaining a stable production process. According to nLight, this elevated power unlocks higher productivity and lower production costs for high-quality parts.The new beam-shaping laser system has already undergone successful commercial validation with an undisclosed customer supporting the aerospace, defense, and automotive markets. This customer has reportedly used the AFX-2000 to 3D print aluminum components three times faster than leading large-format 3D printers.The exclusive beam profiles of the AFX-2000 have brought L-PBF print speeds to exciting new levels while maintaining precision, control and material quality for laser powder bed fusion, explained nLights Chief Technology Officer, Rob Martinsen. He calls the AFX-2000 the most versatile and efficient laser available for metal AM.Visitors to Formnext 2024 in Frankfurt can experience the AFX-2000 first-hand at the nLight booth (hall 12.0, E102).Read all the news from Formnext 2024.During the show, nLight will also host a multi-day seminar series called Powered by Beam Shaping. This will feature insights from industrial 3D printer manufacturers including 3D Systems, Aconity3D, AMCM, DMG Mori USA, EOS, and Nikon SLM Solutions. According to nLight, the series will highlight new applications being unlocked by nLights Corona AFX beam shaping technology.A render of a ring-shaped laser beam profile. Image via nLight.New AFX-2000 beam-shaping laser The Gaussian profile of conventional 3D printing lasers poses challenges for industrial 3D printing. In an interview with 3D Printing Industry, Philipp Kohlwes, the Head of L-PBF at Fraunhofer IAPT, explained that their high-power concentration creates uneven energy distribution. With too much energy in the middle, this profile can vaporize material or create pressure gradients around the melt pool which causes spatter and damages part quality.Laser beam shaping in metal 3D printing overcomes these issues by manipulating the laser beam profile into different shapes before sintering the metal powder. These shapes unlock more even energy distribution in the melt pool. According to Kohlwes, this can improve 3D printing process stability by 40%.Martinsen explained that the dynamic beam-shaping technology in the new AFX-2000 lasers unlocks productivity-optimized switching between ring beam profiles. These donut-shaped profiles are reportedly optimized for fine-scale features and contour exposures, enabling impressive build rates and part reproducibility.The AFX-2000 is currently in production and will be offered in nLights modulus platform. This integrated multi-laser system is designed to facilitate high-productivity LPBF 3D printing. It reportedly simplifies the integration, control and serviceability of multi-laser 3D printers, while maximizing machine utilization and reproducibility.nLight is confident that the AFX-2000 will be widely adopted by those 3D printing with highly reflective alloys like aluminum and copper. These materials benefit from stable, high-brightness laser processing. The AFX-2000 will enable our customers to meaningfully reduce part costs for high-volume manufacturing, added Martinsen.Different laser beam profiles of an nLight AFX-1000 measured at Fraunhofer IAPT. Image via Fraunhofer IAPT.Beam shaping enhances metal 3D printingThanks to its value in enhancing LPBF 3D printing, beam-shaping has witnessed increased commercialization and adoption throughout the metal additive manufacturing industry. Earlier this year, nLight agreed to supply Munich-based 3D printer manufacturer EOS with its AFX programmable 3D printing beam-shaping lasers.Through the joint strategic cooperation, the lasers are available on EOS metal 3D printers. nLights programmable AFX lasers offer seven different donut-shaped beam profiles ranging from 85-micron spot size for precision contours to a 210-micron ring profile for enhanced process stability and reduced soot and spatter. These profiles are now accessible via EOS software and can be altered during 3D printing, with adjustments able to be made in under 30 ms.Additionally, Formnext 2024 will also see the German research organization Fraunhofer Institute for Laser Technology ILT showcase its own new 3D printing beam shaping technology. Developed in collaboration with RWTH Aachen University, the new test system is designed for the investigation of complex laser beam profiles.It can create customized beam profiles for LPBF 3D printing to enhance part quality, process stability and productivity while minimizing material waste. Previously, the creation of complex profiles beyond ring or rectangle shapes has been limited by technological restraints. Fraunhofer IAPTs new platform reportedly overcomes these limitations, facilitating the creation of new beam profiles which meet specific application needs.Who are the leaders in additive manufacturing? Vote now in the 2024 3D Printing Industry Awards!Want to share insights on key industry trends and the future 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What does the future of 3D printing hold?What near-term 3D printing trends have been highlighted by industry experts?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on Twitter, like our Facebook page, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows a render of a ring-shaped laser beam profile. Image via nLight.

According to Thomas Batigne, Lynxters application-based approach unlocks significant growth opportunities within the competitive polymer 3D printer landscape.In a recent conversation with 3D printing Industry, Batigne, the companys CEO, highlighted the importance of addressing customer needs and meeting specific user demands. This approach has enabled the French 3D printer manufacturer to achieve 140% growth over the past year alone.Batigne also outlined the firms multi-pronged product strategy, which sees it offer modular 3D printers and dedicated IDEX systems alongside customer-specific white-label solutions. The latter addresses applications spanning 3D printed medication to reusable aerospace coatings masks.Additionally, he explained how Lynxters user-friendly 3D printing software makes high-quality 3D printing more accessible and discussed Lynxters efforts to expand its global reach to North America and beyond.During the discussion, Batigne identified key market trends and shared his vision for the future of 3D printing. He warned against the emergence of AI-gimmicks and detailed how Lynxter is capitalizing on a maturing industry which is transitioning from novelty to necessity. He also discussed whether the 3D printing industry is consolidating, countering the narrative that recent M&A activity reflects a difficult period that might not be a constructive consolidation yet, but a potential fertile ground for it in the upcoming years.Thomas Batigne, Lynxters CEO. Photo via Lynxter.Lynxters 3D printer portfolioLynxters dual-pronged product approach seeks to meet the evolving needs of the additive manufacturing market. The company offers a modular 3D printing solution as well as dedicated 3D printers optimized for high-productivity production.The former, Lynxters S600D 3D printer, features quick-change tool head capabilities, allowing users to switch between different nozzles for different materials in a matter of minutes. Designed for research and development applications, the S600D is optimized for those exploring new processes and materials and requiring flexibility. The modular 3D printer is notable for its compatibility with Lynxters tool heads for various filaments (FIL11), pastes (PAS11), and liquids such as silicone (LIQ21).Today, some people use the S600D to print materials weve never seen or even envisioned, explained Batigne. He noted that the range of applications for this platform is broad, as customers increasingly integrate third-party modifications to enhance its capabilities.On the other hand, Lynxter also offers specialized extrusion systems for customers seeking a straightforward, turnkey production-grade 3D printer for serial production. Leveraging Dual Extruder (IDEX) technology, these 3D printers include the S300X LIQ21 | LIQ11 and the recently announced S300X FIL11 | FIL11.Launched in 2022, the S300X LIQ21 | LIQ11 stands out for its compatibility with industrial and medical-grade silicones and polyurethanes. This makes it ideal for the production of dampers, seals, skin contact-ready orthoses, functionalized textiles and surface treatment masking devices.The S300X FIL11 | FIL11, set to be officially unveiled at Formnext 2024, is designed to process industrial thermoplastics. It boasts 10,000 mm/s acceleration and 24 mm3/s extrusion capacity, unlocking high-speed, dual-material 3D printing.According to Batigne, the decision to transition from the delta architecture of the S600D to IDEX 3D printing was driven by its application, speed, and cost advantages. He believes tool head independence offers users flexibility without sacrificing productivity. For instance, duplication mode, which simultaneously fabricates two identical parts, instantly doubles 3D printing speeds.Lynxters 3D printer portfolio. Image via Lynxter.Lynxters application-based 3D printersBatigne also outlined how the company collaborates with customers to develop application-based, white-label 3D printers.The approach sees Lynxter take on projects that align with its roadmap, skill sets, and core interests. It empowers the company to place its technology in the hands of experts who can customize it to meet their unique needs. People dont buy a 3D printer; they buy a solution for their problem, added Batigne.The CEO highlighted the pharmaceutical sector as a prime example. Lynxter recently partnered with healthcare firm MB Therapeutics to develop a bespoke system for 3D printing personalized medicine for children. The MED-U Modular and MED-U Prod 3D printers are based on Lynxters S600D and S300X systems. They can 3D print various rheologies like gel or paste, and are compatible with thermosensitive active ingredients. The specialized systems can produce customized medication with individually adjusted dosages, shapes and sizes, meeting individual patient needs.Lynxter has also targeted the aerospace sector by developing solutions for surface treatment. Batigne explained that using masking tape when painting large parts is inefficient and can damage surface quality. 3D printing custom custom plugs from an elastomeric material offers a reusable, time-saving alternative.Lynxter 3D printed applications. Image via Lynxter.Streamlining 3D printing softwareOn the software front, Lynxter offers HUB, its 3D printing platform designed to simplify machine control, documentation, and user interaction. Developed with ease of use in mind, HUB integrates interactive documentation directly on the 3D printer, centralizing key data and information in one place.According to Batigne, Lynxters software expands the companys addressable market. We move from just targeting additive manufacturing enthusiasts to opening up usage for nearly everyone. He added that HUB turns Lynxters industrial 3D printers into a convenience printer by removing the need for knowledge around print preparation and slicing. It also provides easy-to-follow instructions for key functions like feeding materials and cleaning the nozzle, lowering the barrier to entry to additive manufacturing.Lynxter is working to expand the features available on HUB over the next year. Batigne teased that the company will introduce new capabilities for fleet management, allowing manufacturers to streamline operations and manage multiple units efficiently. The company also plans to add tools for resellers, enabling them to utilize HUB for customer support to keep teams in sync with machine diagnostics.Lynxter remains committed to maintaining an open yet straightforward system for its machines. Targeting users who just want a straightforward approach, Batigne emphasized that the companys 3D printers are manufacturing systems and therefore should not be closed.Close-up of a Lynxter silicone 3D printer. Photo via Lynxter.Targeting international expansionBatigne discussed Lynxters international growth trajectory, with the company set to build on its existing presence in Europe, North America, and parts of Asia. The companys main expansion goals include strengthening its presence in Germany and further investing in North America.In Germany, Batigne sees potential for exponential growth, describing it as a dynamic market where Lynxter aims to establish a larger footprint. He called it a neighbors market where they dont have many machines, but the potential is great.Elsewhere, Batigne stated that Lynxter has really great partners in North America. He added that these partners allow us to see significant growth without investing a lot. The company is working to sustain this growth by having more Lynxter people on site over there.Batigne acknowledged the challenges in scaling globally. Establishing the right local partnerships has been crucial while ensuring consistent customer experience across regions is also a priority.Lynxter has also implemented initiatives like reseller days and streamlined communication channels to unify its global network. If a customer in California buys a printer, they should have the same positive experience as a customer in France, he explained. Since launching these initiatives earlier this year, the company has improved partner engagement and customer satisfaction. It plans to continue refining this approach into 2025.Lynxters IDEX 3D printing technology. Photo via Lynxter.Is the 3D printing industry consolidating?Nano Dimensions efforts to acquire Desktop Metal and Markforged have raised questions about the level of 3D printing industry consolidation. Contrary to some narratives, Batigne argued that the sector is not undergoing significant consolidation. Instead, he believes it is purging companies that lack market adaptability.According to Batigne, true consolidation adds value to the customer through the strategic merger of important players with a smart product portfolio. He stated that recent activity has mostly seen larger companies buying failing entities at low costs.Therefore, current mergers and acquisitions, Batigne suggests, represent the purge of the second generationa necessary filtering of companies unable to address real market needs. He believes this process will identify which companies have actual roots within the real market.How will Lynxter approach mergers and acquisitions over the next three to five years? According to Batigne, the company will focus on enhancing its ecosystem for customer benefit rather than accumulating competitors and technologies that dont serve its core mission.Industry trends and the future of 3D printing at LynxterBatigne approaches industry trends with skepticism. In the face of what he calls AI gimmicks and super-high-speed claims that do not add real value, Lynxter is pursuing a pragmatic strategy. The company is prioritizing functional advancements over hype, offering useful features (powered with AI or not) and high-speed 3D printing preserving final parts and machine durability only where they truly benefit the application.Batigne believes the 3D printing industry is transitioning from novelty to necessity, reflecting a key period of market maturity. He remarked, AM isnt cool anymoreits useful, with players who focus purely on technology without having a clear application strategy likely to fail. For the upcoming five years, we will keep growing, he added, highlighting that there remains a substantial market to exploit in terms of applications and territory.While Lynxter has various new products in development, it will selectively introduce them based on specific market demands. The company reportedly still has new extrusion technologies in the pipeline. We have not exploited all of our R&D, explained Batigne. We still have a lot of things we havent commercialized, and we are just waiting for the right moment, right vehicle, and right application to release them.In terms of future 3D printing materials, Lynxter plans to expand its product range with a deep dive into elastomer materials. Batigne identified how various thermoplastics have certifications for specific applications. However, this does not currently exist in the AM elastomeric market (ie. electrostatic discharge (ESD), FDA, flame retardancy).Batigne explained, For example, if you want an ESD-capable polyurethane material for a true elastomeric 3D printer, you cant find it. To address this gap in the market, Lynxter material scientists are working with their partners to support customers targeting specific elastomeric 3D printing.Who are the leaders in additive manufacturing? Vote now in the 2024 3D Printing Industry Awards!Want to share insights on key industry trends and the future 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What does the future of 3D printing hold?What near-term 3D printing trends have been highlighted by industry experts?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on Twitter, like our Facebook page, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows Lynxters silicone 3D printing. Photo via Lynxter.

Australian metal 3D printer manufacturer SPEE3D is introducing its novel Expeditionary Manufacturing Unit (EMU) at Formnext 2024 from November 19-22.This system offers a mobile solution that enables maritime and defense industries to produce essential metal parts on-site, even in remote and challenging environments. Designed to streamline supply chains, the EMU facilitates rapid printing, post-processing, and validation of high-quality metal components exactly where theyre needed, reducing dependence on lengthy logistics and cutting lead times.Visitors can witness the EMUs capabilities, including live demonstrations of the XSPEE3D printer producing metal parts on-site and the latest Nickel Aluminium Bronze (NAB) materials developed with the U.S. Naval Sea Systems Commands SUBSAFE program, at Booth C.01, Hall 12.0. According to the company, this offers a firsthand look at how SPEE3Ds technology transforms operational readiness.EMU in the bush SPEE3Dcell (left) and XSPEE3D (right). Photo via SPEE3D.Comprehensive and mobile manufacturing solutionAccording to the company, the EMU combines the XSPEE3D high-speed metal 3D printer with the SPEE3Dcell post-processing unit within two ruggedized containers, providing a fully transportable setup deployable by truck, ship, or aircraft.Capable of producing large, dense metal parts up to 40 kgs, this system operates in a wide range of materials, including Nickel Aluminium Bronze (NAB), copper, and stainless steel, meeting the durability and corrosion-resistance needs of maritime applications. Moreover, SPEE3Dcell complements the 3D printer with dual heat treatment furnaces, a CNC mill, and testing tools, ensuring seamless on-site processing and quality control.Army soldier removes finished heat-treated Clutch Slave Cylinder from SPEE3Dcell furnace. Photo via SPEE3D.Utilizing SPEE3Ds patented cold spray additive manufacturing (CSAM) process, the EMU binds metal powder into dense, high-strength parts at speeds of up to 100 gms per minute, eliminating traditional casting delays.With NAB as a durable and corrosion-resistant material, SPEE3Ds EMU can produce a 15-kilogram (33-pound) propeller housing in just 4.5 hours, with heat treatment and machining completed within an additional 20 hours. In under 24 hours, maritime operators have a ready-to-use part, providing a rapid alternative to traditional casting methods.Army soldier in CNC and tooling area of the SPEE3Dcell for newly finished Clutch Slave Cylinder. Photo via SPEE3D.SPEE3Ds results in defense trialsSPEE3Ds EMU has undergone extensive testing and successful deployments across multiple defense forces, demonstrating its adaptability and reliability in diverse environments.In the US, the EMU was used during the Rim of the Pacific (RIMPAC) 2024 exercise with the U.S. Department of Defense (DoD), where it provided on-demand part production capabilities in remote settings, showcasing a significant reduction in equipment downtime and logistical costs associated with traditional supply chains.Elsewhere in the UK, the British Army tested the EMU during the AM Village exercise, validating its use in rugged field conditions and highlighting the systems potential for supporting extended operations by eliminating reliance on distant manufacturing facilities.Army soldier reviewing GWagon Alternator Shield print from XSPEE3D. Photo via SPEE3D.Defense forces in Ukraine and Japan also integrated the EMU into their operations, where the technology proved essential for maintaining readiness under various operational demands.For Ukraine, the ability to produce critical replacement parts directly in the field reduced the need for complex logistics, while Japans defense forces benefited from the EMUs rapid production capabilities, which helped address urgent repair needs in maritime settings.Each of these trials underscored the EMUs unique advantage in producing critical components on-site, allowing defense organizations to maintain operational readiness and minimize downtime.Catch up on all the news from Formnext 2024.Voting is now open for the 2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows EMU in the bush SPEE3Dcell (left) and XSPEE3D (right). Photo via SPEE3D.

Researchers from Ritsumeikan University and the University of Science and Technology Beijing, have developed an advanced edge-highlighting method aimed at enhancing the clarity of visualized 3D scanned objects.Led by Professor Satoshi Tanaka and involving key team members Ms. Yuri Yamada, Dr. Satoshi Takatori, and Prof. Liang Li, the groups innovative approach addresses common visualization issues by separately emphasizing sharp and soft edges in complex point cloud data, overcoming limitations seen in traditional methods. Published in Remote Sensing, these findings promise clearer representations of intricate 3D objects, particularly useful for preserving and studying cultural artifacts.Explaining the researchs broader significance, Prof. Tanaka notes, Our 3D edge extraction approach is not merely an improvement but rather an extended technique that captures areas not covered by traditional methods. For archaeologists and historians, this tool opens new possibilities for specialized visual analysis of cultural heritage objects. For the general public, it offers a deeper understanding of historical cultural sites, serving as a technology for enhancing exhibitions in museums and art galleries.Dual 3D edge extraction for 3D scanned point cloud data of the cave of the Zuigan-ji Buddhism temple in Miyagi Prefecture, Japan. Image via Ritsumeikan University.Advancing cultural heritage visualization through enhanced 3D scansWith the rapid advancements in 3D scanning, especially through photogrammetry and laser scanning, researchers can now produce accurate digital representations of complex objects, including cultural artifacts, as detailed point cloud data. These scans allow for an in-depth analysis of structural details but can present challenges in visualization, as traditional edge-highlighting methods often produce excessive lines that reduce visual clarity.To address these challenges, the team developed a dual-edge highlighting approach. This dual-edge extraction technique uses separate thresholds to distinguish sharp edges from softer, rounded ones.Sharper edges are identified through high-curvature zones, while soft edges, essential in rounded or subtler contours, are represented with a secondary threshold. By applying distinct visualization techniques to each, the team captures a fuller range of details without the clutter or thickness that can occur when soft edges are visualized as wide bands.Opacity color gradation further enhances visualization by introducing a color and transparency gradient within soft edges, creating a halo effect that naturally distinguishes front and background edges. Depth perception is thus markedly improved, allowing intricate internal structures to be observed more clearly.To achieve this efficient rendering, the team used stochastic point-based rendering (SPBR), a technique that enables real-time visualization without the intensive depth sorting typically required in 3D processing.In testing, the technique was applied to high-value cultural heritage sites, including Japans Tamaki Shinto Shrine and Indonesias Borobudur Temple.Compared to traditional edge-highlighting, the dual-edge method provided enhanced visual clarity, accurately representing both exterior and interior structures without increasing computation times. The halo effect and edge-thinning significantly clarified intricate details, proving essential for preserving cultural heritage objects.Interactive rendering speeds ensure the techniques functionality for real-time exploration, supporting applications like see-through visualization. Rather than relying on standard transparency, this method uses edge clarity to bring internal structures into view without losing visual depth, a significant improvement in comprehensibility.Future enhancements will focus on refining threshold-setting processes and expanding color gradation pathways to further detail subtle features.Plans to incorporate machine learning into this technique aim to combine 3D restorations with information from sharp and soft edges, particularly beneficial in digitally reconstructing artifacts recorded in 2D formats.This new visualization approach opens a valuable pathway in 3D scanning applications, offering researchers sharper tools for digital preservation, analysis, and exploration of cultural heritage with unprecedented clarity and depth.Dual 3D edge extraction for 3D scanned point clouds of wall reliefs in the Borobudur Temple, a UNESCO Worlds Cultural Heritage, in Indonesia. Image via Ritsumeikan University.Novel 3D scanning approaches for cultural preservationOver the years, various developments have been reported in the 3D scanning for cultural preservation, highlighting the technologys potential. Back in 2022, Ukrainian activists began using 3D scanning to digitally preserve cultural heritage sites endangered by Russian military actions.Through the Backup Ukraine initiative, around 6,000 volunteers used the Polycam app to capture 3D models of monuments and historical sites, safeguarding them against potential destruction. Launched by co-creator Tao Thomsen in partnership with UNESCO and Blue Shield Denmark, the initiative quickly expanded as volunteers documented war damage across Ukraine. UNESCO reported significant destruction to religious and historical sites, underscoring the urgent need for digital preservation to protect Ukraines cultural legacy.Previously in 2018, In 2018, Google collaborated with CyArk, a nonprofit dedicated to preserving historical sites at risk from conflict or natural disasters, to launch the Open Heritage project on Google Arts & Culture.Through CyArks 3D laser scanning expertise, this project generates highly detailed models of cultural landmarks, accessible via Googles platform. Using advanced techniques like LiDAR and photogrammetry, CyArk achieves millimeter-level precision, supporting future restoration efforts. As Google Arts & Cultures first venture into 3D heritage sites, Open Heritage also provides model data for developers interested in creating immersive and educational experiences around these digital artifacts.Voting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows dual 3D edge extraction for 3D scanned point cloud data of the cave of the Zuigan-ji Buddhism temple in Miyagi Prefecture, Japan. Image via Ritsumeikan University.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

Aridditive, a Barcelona-based startup specializing in 3D printing of precast concrete, has successfully closed a 500,000 Pre-Seed funding round, led by BeAble Capital with participation from Suma Capital. The company, which spun off from the Universitat Politcnica de Catalunya (UPC) and CIM UPC, aims to drive digitalization, automation, and sustainability within the construction sector. With this fresh investment and additional support from ACCIs Startup Capital, Aridditive plans to advance its concrete 3D printing technology, promising to transform traditional construction processes.Founded on over a decade of research, Aridditives mission is to accelerate concrete productions shift toward digital processes that optimize every stage of building. Its unique 3D printing technology produces digital twins of precast components, fully automating production while minimizing material waste and energy consumption. With its new funding, the company aims to launch proof-of-concept trials by the end of 2024, with plans for a market debut at a prominent event in spring 2025.Aridditive founders : Roger Uceda & Arnau Cumelles. Photo via Aridditive.Roger Uceda, CEO of Aridditive, credits this milestone to the solid support from UPC and their investment partners. This funding round enables us to take decisive steps in validating our technology and advancing our mission to digitalize and make the construction sector more sustainable, he remarked. Co-founder Arnau Cumelles noted that these developments would showcase the companys potential to redefine precast concrete manufacturing in 2025.With a specialization in early-stage Deep Science investments, BeAble Capital is recognized for bringing cutting-edge industrial technologies from the lab to commercial viability. This latest investment aligns with the firms strategic focus on transformative technologies. Partner Alberto Daz expressed confidence in Aridditives potential: A pioneering technology in 3D printing of concrete, Aridditive is scalable and capable of redefining a key industry like construction, with significant benefits for sustainability and efficiency.Suma Capital, known for prioritizing sustainable investments, regards Aridditives approach as an opportunity to drive an eco-conscious shift in construction practices. Partner Josep Miquel Torregrosa emphasized Sumas commitment to projects that enhance environmental impact. He sees Aridditives technology as a bridge toward efficient, low-impact construction models.Aridditive Logo. Photo via Aridditive.Sustainable Advances in Concrete 3D PrintingThe construction industry faces pressure to innovate amid concerns over concretes environmental footprint. A recent study from ETH Zurich introduced Impact Printing, a new robotic construction technique using Earth-based materials like sand and clay to create structures without cement. Designed as an alternative to traditional concrete methods, this approach reduces CO emissions by using local, recyclable materials and minimizes the need for cement, which is responsible for nearly 8% of global emissions.Simultaneously, researchers at the University of Virginia (UVA) have explored the use of graphene-enhanced concrete to improve strength and sustainability in 3D printed construction. By incorporating graphene nanoplatelets, UVAs team found that the modified concrete achieves a 23% increase in compressive strength and a 31% reduction in greenhouse gas emissions compared to conventional mixtures. These developments underscore a broader shift toward sustainable building materials, positioning Aridditives innovations within an industry moving away from emissions-intensive practices.This visualisation shows layers of graphene used for membranes. Image via University of Manchester.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured image shows Aridditives Logo. Photo via Aridditive.

Endless Industries GmbH, an advanced manufacturing firm based in Berlin, will unveil its latest medium-scale continuous fiber 3D printer, the Endless ONE, at Formnext 2024. Targeting sectors with demanding structural needs such as aerospace, automotive, and medical, the machine employs continuous carbon fiber printing to produce lightweight, high-strength components with a high degree of customization.Unlike conventional polymer or metal powder-based 3D printing, continuous fiber technology integrates uninterrupted carbon fibers directly into the printed structure. This process delivers significant mechanical durability suited for applications where strength-to-weight ratios are crucial. The printers 600 mm 400 mm 440 mm build volume and open-material compatibility further support industrial applications requiring a high degree of adaptability in part design.Endless ONE medium-scale continuous fiber 3D printer. Photo via Endless Industries.Stephan Krber, CEO of Endless Industries, emphasized the strategic significance of the Endless ONEs launch. Our goal is to demonstrate how continuous fiber 3D printing can meet the structural demands of various industries efficiently, Krber stated. He further explained that the company aims to make large-scale 3D printing more accessible by focusing on technologies combining high performance and adaptability.The company will demonstrate two critical applications at Formnext. One use case lies in orthotic manufacturing, where technicians can produce custom lightweight orthoses tailored to patient needs. Current orthotic production methods struggle to balance strength with weight due to high material costs and manufacturing complexity. The new printers continuous fiber capabilities allow efficient production of durable orthoses, enhancing cost-effectiveness and personalization in patient care.Another application involves tooling for high-pressure composite manufacturing environments. Molds for composite parts, typically manufactured from costly metal or composite materials, must withstand high autoclave temperatures and pressures. Endless Industries device allows for 3D printed tooling that meets these demands while reducing cost and production time, positioning it as a practical alternative for sectors like aerospace that depend on high-performance tooling.Formnext 2024 attendees can view the printer in action at Booth 11.1 D31 and discuss its industrial applications with Endless Industries representatives.Carbon spring 3D printed using Endless One. Photo via Endless Industries.Industry Developments at Formnext 2024Formnext 2024 will feature several advancements in 3D printing technology from other industry players. South Korean company InssTek will present its MX-Lab 3D printer, designed for precise alloy research and aerospace manufacturing. The MX-Lab features six independently controlled powder feeders and a Ytterbium Fiber Laser operating between 300 W and 500 W, facilitating in-situ alloying and material research. With a build volume of 150 mm 150 mm 150 mm and a compact footprint, the MX-Lab supports rigorous testing and development of multi-material aerospace components, such as rocket nozzles.French manufacturer Lynxter will introduce the S300X FIL11 | FIL11, a high-speed dual-extruder 3D printer designed for industrial thermoplastics. The S300X boasts an acceleration of 10,000 mm/s and an extrusion capacity of 24 mm/s, making it one of the fastest material extrusion (MEX) machines available. It supports a range of high-performance materials, including PEKK and TPE/TPU, and features an industrial-grade HEPA H14 and active carbon filtration system to mitigate harmful emissions during printing. Lynxters printer is engineered for high productivity and material versatility, catering to industries that require robust and high-quality parts.Duplication mode on Lynxters new S300X FIL11 | FIL11 3D printer. Photo vis Lynxter.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured images showcase the Endless ONE medium-scale continuous fiber 3D printer and a Carbon spring 3D printed using Endless One. Photos via Endless Industries.

Formnext is getting closer, I asked event organisers Mesago a few questions about what attendees can expect.All the news from Formnext 2024.What are the highlights attendees can expect from Formnext 2024?Formnext 2024, taking place from 19-22 November in Frankfurt, promises to be an exciting event for additive manufacturing professionals and enthusiasts. The additive manufacturing industry remains optimistic in autumn 2024, despite economic challenges. According to a VDMA survey, revenues are stable, with 65% of companies expecting domestic growth and 58% anticipating export growth. At the moment companies are cautious about investments due to the strained economic situation, the geopolitical situation and the transformation in which many companies currently find themselves. Even in economically challenging times, Formnext in Frankfurt, with around 860 exhibitors and 55,000 square metres of exhibition space, is again the outstanding platform for the global elite of additive manufacturing.Here are some key highlights attendees can expect on the showfloor:Comprehensive stage programFormnext will again feature discussions on current and future applications, technologies, and trends in the AM and manufacturing industry across three stages. Key topics include sustainability, medical and dental technology, aviation and aerospace, and automation, and many more.Discover3Dprinting seminars will offer valuable orientation for beginners each morning on the Application stage and 4 Deep Dives will delve into 4 major AM topics.The Pitchnext event will give young companies the opportunity to present themselves to potential investors and partners on Tuesday on the Industry Stage, while being available for further discussions at the Start-up Area.Showcases and events VDMA will present a showcase AM4Industry highlighting valuable AM applications in mechanical engineering The BE-AM symposium on 20 November and the BE-AM showcase will demonstrate advanced developments in AM for the construction industry The AM Innovation and Standards Summit will bring together industry leaders to discuss the latest innovations and standardization efforts one day prior to Formnext on 18 November. The Career Day will provide insights into job opportunities in the AM industry on Thursday, 21 November. New Award Concept with 6 categories Service Provider MarketplaceWhat new technologies or products will be showcased at Formnext this year?The around 860 exhibitors at Formnext 2024 present many innovations, especially in the field of material development. New high-performance polymers and metal alloys offer solutions for extreme applications. The use of artificial intelligence and machine learning to optimize production processes will also be increasingly addressed. Hybrid processes that combine additive and subtractive manufacturing help to increase efficiency. Sustainability remains a key issue with developments aimed at recycled materials and energy-efficient printing processes. These advances show how 3D printing continues to establish itself as a technology and create new opportunities for various industries. And especially in economically uncertain times, AM solutions also offer economic advantages in competition.Do you see any trends in the industry this year?AM is seeing increased adoption across critical sectors like aerospace, healthcare, automotive, and consumer goods. The technology is moving beyond prototyping into end-use part production. The industry is moving towards increased automation and precise process control, integrating advanced software systems to streamline production and ensure quality. Additionally, AM is increasingly integrating with other digital technologies like artificial intelligence, machine learning and augmented reality to enhance design processes, tracking, and supply chain management. Theres a focus on improving the speed, efficiency, and productivity of AM processes. These trends indicate that the AM industry is rapidly evolving, with a focus on expanding applications, improving efficiency, and integrating with other advanced technologies to drive innovation in manufacturing.What is new for this years show?Partner Country: AustraliaAustralia, this years partner country, will showcase its strong AM community and globally successful companies. This partnership offers exciting insights into the innovative power of this fascinating country.Formnext AwardsFormnext is putting exceptional talents and ideas from the world of Additive Manufacturing in the spotlight with its new awards format. This year, for the first time, the Formnext Awards will be presented across six different categories, including young innovative companies, sustainable business ideas, and pioneering technologies.How can attendees and exhibitors optimise their time in Frankfurt?To optimize your visit to Formnext 2024, consider the following strategies:Plan Ahead: review the exhibitor list and floor plan in advance to identify key companies and technologies you want to see. Use the Formnext Navigator app to create a personalized schedule and map out your route through the exhibition halls. Check the agenda for the 3 stages and add presentations to your agenda that align with your interests. Especially, events like the News, Morning talks, Pitchnext Event for startups and the panel discussions on important industry topics can provide valuable insights in a relatively short amount of time.How do you think artificial intelligence and machine learning will influence additive manufacturing in the future?Artificial intelligence and machine learning will significantly enhance additive manufacturing by optimizing processes through real-time parameter adjustments and predictive maintenance to reduce downtime. They will improve quality control by enabling real-time defect detection and proactive management during printing. AI will facilitate generative design and topology optimization, allowing for more efficient and innovative product designs. In material development, machine learning will accelerate the discovery of new materials by predicting their properties and matching them to specific AM processes. Furthermore, AI will streamline simulations, making them faster and more accurate. It will also optimize supply chains through better demand forecasting and decision-making in distributed manufacturing. Finally, AI and machine learning will enable automated customization, allowing for efficient mass production of tailored products. Overall, these technologies will make AM processes more efficient, adaptable, and capable of producing complex designs.How do you think the event contributes to the growth of the additive manufacturing industry?Formnext significantly contributes to the growth of the additive manufacturing industry by showcasing cutting-edge innovations and new technologies from leading companies. It facilitates knowledge exchange through discussions on current trends and applications, enhancing industry learning. By attracting the largest global crowd in AM, Formnext offers extensive networking opportunities, connecting professionals and fostering collaborations that drive growth. By supporting start-ups through initiatives like the Formnext Start-up or Rookie Award, it introduces fresh ideas and innovations into the market. Finally, as a global event, Formnext provides international exposure for companies, helping to expand markets and accelerate global adoption of AM technologies.What aspects of Formnext do you find most valuablenetworking, product showcases, workshops, etc.?All of these aspects of Formnext are very relevant, but visitors may prioritize them differently depending on their focus. Nevertheless, exhibitions are the best way to get in touch.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What3D printing trendsdo the industry leaders anticipate this year?What does theFuture of 3D printinghold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the3D Printing Industry newsletteror follow us onTwitter, or like our page onFacebook.While youre here, why not subscribe to ourYoutubechannel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows Formnext at Messe Frankfurt. Photo by Michael Petch.Michael PetchMichael Petch is the editor-in-chief at 3DPI and the author of several books on 3D printing. He is a regular keynote speaker at technology conferences where he has delivered presentations such as 3D printing with graphene and ceramics and the use of technology to enhance food security. Michael is most interested in the science behind emerging technology and the accompanying economic and social implications.

In alliance with IPEX Technologies, JuggerBot 3D has introduced the Tradesman Series P3-44 ASTRA, a large-format additive manufacturing (LFAM) system designed specifically to manage the challenges of polyvinyl chloride (PVC) processing in industrial contexts.Equipped with pellet-fed extrusion technology, this system is developed to enhance the scope of industrial 3D printing opening up new approaches for creating PVC-based components and end-use parts. Valued for properties like chemical resistance, flame retardancy, and mechanical strength, PVC is produced globally at rates exceeding 50 million tons per year, according to the company.Despite these advantages, AM has seen limited application of PVC due to the need for strict fume management and specific material handling controls. As a result, Juggerbots P3-44 ASTRA directly addresses these requirements through advanced process controls and robust safety systems, prioritizing both operator safety and equipment protection while ensuring environmental care.This project represents an important step forward in additive manufacturing for industrial materials, said Brian Zellers, Product Development Manager at JuggerBot 3D. We take pride in proclaiming that we can process a wide array of performance thermoplastics, including PVC. By advancing preexistent process controls in our base P3-44, weve developed a system that offers safety and performance, enabling operators to leverage PVCs material benefits through reliable 3D printing technology.Tradesman Series P3-44 Astra model. Photo via Juggerbot 3D.Advanced safety and fume control for reliable PVC processingIncorporating JuggerBot 3Ds expertise in material testing and control processes, the ASTRA model is based on the Tradesman Series P3-44.It includes corrosion-resistant components and an enhanced fume extraction system precisely positioned at the point of print deposition, maintaining the structural integrity and core features of the original unit. Such adaptations allow it to handle the distinct needs of PVC, making it effective in scenarios where consistent processing and protection against fumes are essential.Designed with advanced safety protocols, the P3-44 ASTRA utilizes corrosion-resistant materials that not only prolong the systems life but also ensure steady control over PVC processing. Additional hardware has been integrated to prevent corrosion and regulate extrusion temperatures accurately.To manage the release of volatile organic compounds (VOCs) during production, sealing has been added to keep fumes within controlled areas, while the dual-stage extraction system actively captures emissions throughout the printing cycle. Chamber access remains restricted until emissions clear, helping to protect operators from premature exposure.Industries requiring materials with PVCs durability and chemical stability, such as those producing body molds, ducting systems, and medical enclosures, are ideal sectors for the P3-44 ASTRA.By supporting high-demand environments where material performance is critical, the system enables these industries to benefit from the unique properties of PVC within additive manufacturing.Tradesman Series P3-44 Astra pipe comparison. Image via Juggerbot 3D.Technical specifications and pricingInterested customers can request a quote from Juggerbot to learn about the ASTRA models price.Build Volume36 x 48 x 48 in (914 x 1219 x 1219 mm)Machine Footprint73 x 125 x 101 in (1854 x 3175 x 2565 mm)Machine Weight4,400 lbs (1,996 kg)SafetyMachine Access Sensors, Lockout/Tagout on PowerPower Requirements Printer208V / 100A / 60Hz / 3Ph w/Neutral and GroundPower Requirements Dryer208V / 30A / 60Hz / 3Ph w/Neutral and GroundAir RequirementsMin 95psi, 4CFMExtruder ThroughputUp to 15 lbs/hr (6.8 kg/hr)Max Nozzle Diameter 0.24 in (6 mm)Max Extruder Temperature752F (400C)Max Platen Temperature248F (120C)Max Chamber Temperature203F (95C)Dryer Capacity100-150 lbs (45 68 kgs)Travel Speed (XY)Up to 19.7 in/sec (500 mm/sec)Suggested Layer Height0.030 0.089 in (0.75 2.25 mm)ConnectivityUSB, Wi-Fi, EthernetOperating SystemWindows 10Machine ControlJuggerBot 3D Control CenterTool Path GenerationORNL Slicer 2Remote Login ControlPre-installedAdditive Manufacturing ProcessFused Granulate Fabrication / Pellet-fed 3D PrintingVoting is now open for the2024 3D Printing Industry Awards.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows the Tradesman Series P3-44 Astra model. Photo via Juggerbot 3D.Ada ShaikhnagWith a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

A recent advance in bioprinting from the Collins BioMicrosystems Laboratory at the University of Melbourne could significantly reshape tissue engineering. Researchers at the lab, led by biomedical engineer David Collins, have introduced a new 3D bioprinting approach called Dynamic Interface Printing (DIP). Unlike traditional methods that slowly build tissue layer by layer, DIP employs acoustic waves to guide cells into precise configurations, producing complex human tissues in secondsa process previously hindered by speed and structural limitations. This breakthrough offers the potential for customized, high-fidelity tissue structures with applications across regenerative medicine and disease modeling. The approach can reportedly achieve 3D printing speeds around 350 times faster than those of traditional bioprinters, reducing the chances of cell damage while maintaining high structural accuracy.Most current bioprinters rely on layer-by-layer construction, which often compromises cell viability due to prolonged exposure times and complex post-processing steps. Once printed, tissue structures typically require delicate handling to avoid damage, which can be difficult when transferring the constructs to lab plates for imaging. DIP, however, addresses these issues by using acoustic waves to position cells at a much faster rate, allowing structures to form directly onto lab plates without additional handling. This innovation protects cell cultures and enables greater customization for various tissue types, from brain tissue to cartilage.Close-up of the DIP System in Action. Photo via University of Melbourne.David Collins, head of the Collins BioMicrosystems Laboratory, explains, Current 3D bioprinters depend on cells aligning naturally without guidance, which presents significant limitations. Using DIP, cells are guided by soundwaves that vibrate microscopic bubbles in specific directions, enabling precise cell placement and eliminating many of the risks associated with conventional bioprinting. Advantages of Dynamic Interface Printing: Versatility and EfficiencyThe DIP process is distinct for its capacity to handle opaque materials and its compatibility with a range of biomaterials without the need for complex optical systems. For instance, DIP can print directly onto lab plates, thereby avoiding steps that may compromise cell viability. This feature not only enhances the integrity of the printed structures but also improves scalability for research and medical applications. Additionally, the acoustic modulation aspect of DIP creates an environment where cells experience minimal mechanical stress, preserving their function and viabilityan essential factor for building effective tissue models.Beyond preserving cell integrity, the process allows for unique biofabrication capabilities, including the creation of intricate multi-material structures and functional components. Acoustic waves within the DIP framework can create hydrodynamic fields, enabling precise 3D particle patterning that proves beneficial in assembling cell-laden constructs. By sidestepping the limitations of traditional volumetric printing, DIP achieves a degree of detail and functionality that broadens its applications in tissue engineering.With the potential to produce patient-specific tissue models rapidly, DIP may soon revolutionize research and personalized healthcare. Researchers at the Collins BioMicrosystems Laboratory are already investigating enhancements for the platform, such as refined control over acoustic fields for even more precise cell arrangements. In the future, DIP could allow medical facilities to bioprint hundreds of miniature tissue models from a patients own cells, boosting the possibilities in diagnostics, drug testing, and regenerative medicine.Illustration of the Dynamic Interface Printing (DIP) Process. Photo via University of Melbourne.Innovations in BioprintingRecent bioprinting developments aim to improve tissue fabrication by more closely mimicking natural cellular environments. Ronawks Bio-Blocks, for instance, create cellular conditions that allow cells to grow in three-dimensional forms. By replicating tissue conditions, Bio-Blocks enhance cell viability and function, enabling insights into cellular processes like protein production and cell signaling, which are crucial for developing new biological therapies.Additionally, BIO INXs collaboration with Readily3D has introduced volumetric 3D printing methods focused on precision and efficiency. Their READYGEL INX bioink uses low-light dose printing to create cell-compatible structures rapidly and with high resolution, offering an optimized solution for fabricating complex biological models while minimizing cell stress. These advances reflect a shift toward biofabrication systems that support viable, detailed tissue structures for research and medical applications.Bio-Blocks allow researchers to observe how a tissue-mimetic environment impacts processes like cell proliferation, extracellular vesicle (EV), and protein production. Image via B9Creations.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured Images showcase A close-up of the DIP System in Action and an illustration of the Dynamic Interface Printing (DIP) Process. Photo via University of Melbourne.

As a critical component of additive manufacturing, Large-Scale High-Speed SLA Technology maintains a prominent position in the field of vat photopolymerization 3D printing for productive and precision production purposes.In todays increasingly competitive market, characterized by saturation and ambiguous growth trajectories, we seek to understand the true value of large-scale SLA 3D printing, its applications focus, and its future prospects.UnionTech, a company deeply committed to continuous innovation in SLA 3D printing, focuses on problem-oriented research and development, guided by practical insights from the frontline. We aim to deliver intelligent, high-quality, and cost-effective professional-grade SLA solutions across various industries, including manufacturing, molding, and direct production of end-user components.In this webinar, we welcome Stanley Leung, Sr. Director of Sales, APAC, UnionTech. Stanley will explore the transformative advantages of UnionTechs proven SLA technology, emphasizing product lines, applications, material options, and notable user cases from VIP customers.What to expect during the webinar An overview of UnionTechs materials and technology, highlighting their turnkey advantages. The benefits of large-scale SLA 3D printing and its value proposition for targeted application groups. An exclusive look at use cases across sectors such as tire molding, automotive, cultural construction, architecture, and more. Live Q&A session. 100 free expo passes for Formnext 2024 will be available for attendees!Register now.Michael PetchMichael Petch is the editor-in-chief at 3DPI and the author of several books on 3D printing. He is a regular keynote speaker at technology conferences where he has delivered presentations such as 3D printing with graphene and ceramics and the use of technology to enhance food security. Michael is most interested in the science behind emerging technology and the accompanying economic and social implications.

AM Efficiency, a Swedish company specializing in post-processing solutions for additive manufacturing, has introduced UNPIT, an automated machine designed for entry-level Selective Laser Sintering (SLS) 3D printers. Making its debut at Formnext 2024 in Frankfurt this November, the new machine automates key stages of post-processingunpacking, depowdering, cleaning, and material recoveryand is capable of reclaiming up to 100% of unused powder. This feature marks a significant advancement in reducing material waste and lowering operational costs for small and medium-sized enterprises (SMEs) engaged in 3D printing.Compatible with popular SLS printers from brands like Sinterit, Sintratec, and Formlabs, UNPIT integrates seamlessly into existing workflows. Users simply place their printed part cakes into the machine, which then completes the entire post-processing sequence without further intervention. This automation minimizes manual labor, reduces the cost per part, and enhances overall production efficiency.The new AM Efficiency UNPIT. Photo via AM Efficiency. The development of the new system involved collaboration with Siemens, leveraging their expertise in automation and digitalization to enhance the machines capabilities. This partnership was crucial in achieving the high level of automation and efficiency that UNPIT offers, ensuring that the machine meets the rigorous demands of modern additive manufacturing processes.We developed UNPIT to address the bottlenecks in the post-processing phase of SLS 3D printing, said Casper Rosn, CEO of AM Efficiency. By automating these steps, companies can focus more on their core activities and innovation, rather than being bogged down by time-consuming manual tasks.Shipments are scheduled to begin in early 2025, following its official launch at Formnext 2024. AM Efficiency anticipates that the machine will be well-received by entry-level SLS users seeking to optimize their post-processing workflows and reduce material costs.UNPIT Logo. Image via AM Efficiency. Industry Moves Towards Automated Post-ProcessingThe introduction of UNPIT aligns with a broader trend in additive manufacturing towards automation. Rivelin Robotics, a UK-based firm specializing in post-processing for metal 3D printed parts, is leading a government-funded project known as Project CAMPFIRE to deliver automated finishing for aerospace components, orthopedic implants, and gas turbine parts. Collaborating with companies like Attenborough Medical and GKN Aerospace, Rivelins Netshape Robots use 3D vision and force control algorithms to minimize human input in post-processing tasks.Similarly, Additive Manufacturing Technologies (AMT) recently launched the PostPro DPX, a depowdering system aimed at the non-industrial 3D printing market. Priced at 15,995, the DPX complements desktop 3D printers from brands such as Formlabs and Sinterit. The system offers automated depowdering, a compact design, and advanced filtration, catering to industries like dental, jewelry, and prototyping that require efficient post-processing solutions.The PostPro DPX depowdering system. Image via AMT.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured images showcase The new AM Efficiency UNPIT and UNPIT Logo. Photos via AM Efficiency.

As voting in the 3D Printing Industry Awards continues, we profile the enterprises at the forefront of 3D printing technology and the related ecosystem.Onome Scott-Emuakpo is the founder of Hyphen Innovations, nominated for 3D Printing Industry Start-up of the Year 2024.Hyphen Innovations is tackling the challenge of making parts better and more efficient, a goal that involves addressing intricate R&D issues such as enhancing material data accuracy, optimizing part designs for durability and performance, and speeding up the production of next-generation components in a cost-effective manner. This work is crucial for advancing industries that rely on cutting-edge engineering, from Aerospace and Defense to new and promising markets like golf equipment, where Hyphens innovative vibration suppression technology, The i-DAMP Method, offers game-changing potential.Onome Scott-Emuakpor. Photo via Hyphen InnovationsWhat problem are you solving, and why is it important?Onome Scott-Emuakpo: At a high level, Hyphen simply wants to make parts better. This statement is packed with complex R&D challenges like getting faster and more accurate material data, designing parts that wont break and that function with precision, and manufacturing next generation parts in a faster, more affordable way.Who is your target market?Onome Scott-Emuakpo: Most of our R&D work is motivated by the Aerospace and Defense industries. But over the last year, weve seen how the physics of aerospace solutions translates to several other industries. Perhaps the market that is most exciting to us these days is golfing equipment, where the impact and shock phenomenon seem ideal for our vibration suppression technology: The i-DAMP Method.Also, our Accelerated Fatigue Testing Machine has garnered plenty of interest from alloy developers and AM process optimization researchers looking to get material property data in hours versus months, which supports faster iterations and faster innovation.Who are the founders and core team members, and what is their experience in this industry?Onome Scott-Emuakpo: When I started Hyphen, I knew I needed someone with similar technical experience as me: over 20 years of turbine engine structural integrity research. I also knew I needed someone with operational and project management experience to provide financial and logistical guardrails to our wild innovation ambitions. I could not have asked for better core team members than Phil and Aaron. Philip Johnson is our Laboratory Director, and Aaron Wearren is our Director of Operations. Between the three of us, we lead a team of six full-time and four part-time employees.What technical challenges have you encountered so far, and how did you overcome them?Onome Scott-Emuakpo: The biggest technical challenge we have encounters has been creating our accelerated fatigue testing machine. Our goal with inventing the testing machine was to take a fatigue testing system with over a million dollars in components and equipment and turn it into a tabletop system that was less than 10% in overall cost. Trying to reduce cost and size while also increasing cycling rate to be faster than standards required optimization of limited power and space, large force movement, and negligible system damping. We overcame the problem by partnering with electrodynamic and laser measurement companies, which allowed us to focus on designing the test for optimal size and force.Who do you consider to be the competition in this market? How does your proposition meet underserved needs or outperform?Onome Scott-Emuakpo: Hyphen focuses on R&D. We bring concepts to reality. From this sense, many companies could be considered our competitors. When it comes to designing lighter and damage resistant parts, companies like nTopology for lightweighting, Moog for vibration suppression, or LSP Technology for damage resistance can be considered competitors. On the fatigue side, MTS Systems Corporation, Zwick, or Shimadzu provide machines for testing as we do. However, what Hyphen Innovations brings to the table is so distinct from each of these companies that we could be deemed complimentary versus competitors. No other company provides an inherent design of parts that can suppress vibration, absorb shock and impact, and resist damage like Hyphen Innovations with the i-DAMP Method. Also, no other company provides a fatigue testing machine that runs on 110V powder, is 250 times faster than standard, and requires no system alignment or specimen tuning to operate. What we do is truly unique and is geared towards creating new industries versus competing in traditional markets.What milestones have you achieved, and what are your next major goals?Onome Scott-Emuakpo: Our key performance indicators this year was to secure defense contracts with multiple agencies in the DoD, achieve service agreements with up to five new customers, and finalize the invention of our accelerated fatigue testing machine to be ready for service and leasing. We have achieved all of our goals this year already. Our goals next year are to double our full-time manpower by the end of the year, secure a partnership agreement with a production corporation capable of taking our accelerated fatigue testing machine to mass production, and demonstrate The i-DAMP Method capability in a consumer-ready golf club.Want to share insights on key industry trends and the future of 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What 3D printing trends do the industry leaders anticipate this year?What does the Future of 3D printing hold for the next 10 years?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook.While youre here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Michael PetchMichael Petch is the editor-in-chief at 3DPI and the author of several books on 3D printing. He is a regular keynote speaker at technology conferences where he has delivered presentations such as 3D printing with graphene and ceramics and the use of technology to enhance food security. Michael is most interested in the science behind emerging technology and the accompanying economic and social implications.

German research organization Fraunhofer Institute for Laser Technology ILT will showcase its new 3D printing beam shaping technology at Formnext 2024.Working with the Chair of Technology of Optical Systems (TOS) at RWTH Aachen University, the new platform, the Fraunhofer team is developing a test system for investigating complex laser beam profiles.This platform can create customized beam profiles for laser powder bed fusion (LPBF) 3D printing, enhancing part quality, process stability and productivity, while minimizing material waste.Fraunhofer ILTs new system uses Liquid Crystal on Silicon Spatial Light Modulators (LCoS-SLMs) to selectively bend the phase front of the laser beam during 3D printing. It can reportedly achieve more complex profiles than the basic ring and rectangular shapes achieved in previous research. This will allow researchers to investigate almost any beam profile used in LPBF. The complex profiles can then be matched with specific industrial 3D printing applications to unlock optimal results and address production demands.We can optimize the LPBF process in a targeted manner, explained Marvin Kippels, a PhD student in the Laser Powder Bed Fusion Department at Fraunhofer ILT. He noted that the new platform will enable less material evaporation, reduce splatter formation, improve melt pool dynamics, smoothen melt track surfaces, and enhance process efficiency.The new LPBF beam-shaping system, currently under construction, will be presented for the first time later this month at Formnext 2024, located in Hall 11.0, booth D31.Marvin Kippels, a doctoral student in the Laser Powder Bed Fusion Department at Fraunhofer ILT. Photo via Fraunhofer ILT.What is laser beam shaping?Laser powers of 300 to 400 watts are used in many LPBF 3D printing processes. The standard Gaussian profile of these lasers presents challenges for industrial applications where quality, efficiency and reliability are key.Philipp Kohlwes, the Head of L-PBF at Fraunhofer IAPT, previously told 3D Printing Industry that the high power concentration of Gaussian lasers creates uneven energy distribution with too much energy in the middle. This can cause local overheating, unwanted material evaporation, and process instability, leading to spatter and pores which damage part quality. These issues limit the scalability of LPBF 3D printing, restricting the maximum laser power which can be used for most materials.According to Kippels, one way to overcome this is through the use of several lasers and optical systems in parallel. However, the costs scale at least proportionally to the number of systems installed, he stated. Additionally, these systems cannot always be used homogeneously, limiting their scalability for industrial applications.To overcome these challenges, Fraunhofer IAPT is investigating laser beam shaping to increase the productivity of single lasers which can also be used in multi-beam 3D printers. In this process, the lasers Gaussian profile is manipulated into different shapes before sintering the metal powder. These shapes can facilitate even energy distributions, translating to more energy in the melt pool. Kohlwes claims this homogeneity can increase metal 3D printing productivity by up to 2.5 times, and improve process stability by 40%.Previous studies have demonstrated that simple beam shapes like rings, rectangles, or a combination of the two can enhance part quality and process speed. However, the creation of more complex beam shapes remains largely unexplored due to limitations in the existing technology.Fraunhofer IAPTs new platform reportedly overcomes these limitations, representing a new step for more complex shapes that can be customized to meet production needs.The potential value of this capability was heralded by Kohlwes during last years interview. The better the laser beam profile is matched to the respective application, the better the energy input and the associated process stability, he emphasized. Similarly, Kippels explained that There is no one perfect beam shape; every application has its own requirements.Redistribution of the laser beam intensity during propagation after reflection at a phase mask of an LCoS-SLM. The initial distribution is on the left and the target distribution on the right. Image via Fraunhofer ILT.Fraunhofers new LPBF beam-shaping platformThe teams new platform leverages LCoS-SLMs to unlock virtually any laser beam profile for LPBF 3D printing. With a maximum laser power of 2 kW, the test system can also assess beam shapes at high power levels, allowing the ideal profile to be matched for specific applications.Fraunhofer ILTs new laser beam shaping platform. Photo via Fraunhofer ILT.According to the Fraunhofer researchers, previous studies in beam shaping have not been based on an in-depth understanding of the underlying process mechanism. This has sometimes created contradictory literature on the subject.Therefore, a more fundamental understanding of processes is needed before researchers can effectively determine laser characteristics, like melt track geometry. To achieve this, beam shapes need to be optimized for specific applications before being adopted by manufacturers. Fraunhofer IAPTs new platform reportedly allows customers and project partners to access its flexibility for researching laser beam shaping to optimize LPBF 3D printing.We are still at the very beginning, but we can already see the enormous potential that beam shaping can offer for the LPBF process, added Kippels. Thanks to our flexible beam shaping, we can find the ideal distribution for each process, the best process parameters for the task in question.Novel laser beam profile created using Fraunhofer ILTs beam shaping platform. Image via Fraunhofer ILT.Advancing laser beam shaping 3D printingGiven its notable advantages for industrial metal 3D printing, beam shaping capabilities are being developed and commercialized by several players in the research and LPBF 3D printing spheres. Semiconductor and fiber laser specialist nLight is one such company. It agreed to supply Munich-based 3D printer manufacturer EOS with its AFX programmable beam-shaping lasers earlier this year.The joint strategic cooperation made the lasers available on EOSs metal 3D printers, while also implementing other complementary laser-based technologies to enhance their light engines for industrial applications. nLights AFX laser technology had previously been made available on metal 3D printers from AMCM, an EOS Group company.Elsewhere, Equispheres and Aconity3D used laser beam-shaping 3D printing to achieve build rates nearly nine times higher than industry norms. Equispheres NExP-1 aluminum powder was used with Aconity3Ds AconityMIDI+ LPBF 3D printer to unlock speeds exceeding 430 cm3/hr for a single laser.The system was modified to employ a PG YLR 3000/1000-AM laser with beam-shaping capabilities. By using a shaped beam over a zoomed Gaussian profile, the team reduced overheating and mitigated spatter formation during high-speed 3D printing.Who are the leaders in additive manufacturing? Vote now in the 2024 3D Printing Industry Awards!Want to share insights on key industry trends and the future 3D printing? Register now to be included in the 2025 3D Printing Industry Executive Survey.What does the future of 3D printing hold?What near-term 3D printing trends have been highlighted by industry experts?Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us on Twitter, like our Facebook page, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.Featured image shows Fraunhofer ILTs new laser beam-shaping platform. Photo via Fraunhofer ILT.

Researchers at New York University (NYU) have engineered a 3D printed model that recreates the nutrient-deprived conditions fostering cancer spread, or metastasis. Published in Life Science Alliance, this breakthrough model enables the direct observation of metastatic behavior in real-time, providing researchers with unprecedented insights into a critical stage in cancer progression often hidden in live patients and traditional models.Design and implementation of a metabolic microenvironment chamber for 3D cultures. Photo via NYU.Metastasisthe movement of cancer cells from the primary site to other organsaccounts for most cancer-related fatalities. While advancements in cancer treatment have improved overall prognoses, metastasis presents persistent challenges. NYUs 3D microenvironment chamber, known as 3MIC, uses live microscopy to capture how cancer cells acquire metastatic traits within oxygen-deprived, low-nutrient zones deep within tumors. Carlos Carmona-Fontaine, an associate professor at NYU and the studys lead author, highlights this step as a critical frontier in cancer research. Witnessing the transition of a tumor cell to a metastatic state could be transformative, he noted, underscoring the difficulty of observing such events in conventional models.Using precisely engineered geometry, 3MIC illuminates cancers behavior in extreme conditions, where resources are scarce and traditional treatments often fail. Carmona-Fontaines team noted that established therapies like Taxol, effective under normal conditions, showed limited efficacy in targeting cancer cells deprived of nutrients and oxygen. This discovery suggests that the diminished response to drugs in metastatic cancers may result from cellular adaptations rather than reduced drug access.Time-lapse of Cancer Cell Behavior Under Different Conditions. Photo via NYU.Developments in 3D Printed Tumor ResearchIn 2023,CELLINK collaborated with Carcinotech to advance cancer drug development using 3D printed tumor models. This partnership focuses on developing and commercializing protocols for biofabricating 3D printed tumor models using various cancer cell lines. By leveraging CELLINKs BIO CELLX system, the collaboration aims to enhance the accuracy and speed of drug testing processes, thereby reducing development costs and improving research outcomes. The protocols developed are designed to incorporate a physiologically representative ratio of five key cell types relevant to each cancer type, ensuring that the models accurately reflect the tumor microenvironment.Additionally, researchers at Tel Aviv University developed a 3D printed glioblastoma model using patient-derived cells to create personalized tumor environments. This model represents the first fully functioning 3D replica of a glioblastoma tumor, including the surrounding tissues that influence its development. By enabling the creation of 100 tiny tumors from a single patient sample, the model facilitates the rapid screening of multiple drug combinations to identify the most effective treatments. Additionally, the TAU team used this technology to target specific protein mechanisms that contribute to immune system-mediated tumor spread, successfully delaying glioblastoma growth and inhibiting its progression.CELLINK BIO CELLX 3D biodispenser. Photo via CELLINK.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured Images showcase the Design and implementation of a metabolic microenvironment chamber for 3D cultures and a Time-lapse of Cancer Cell Behavior Under Different Conditions. Photos via NYU.

Beth Le, a designer active on Printables, a platform for sharing 3D printing designs, has introduced the Beth Deck, a 3D printed gaming handheld that repurposes Frameworks 13-inch laptop mainboards. This project allows users to assemble a portable gaming device in approximately fifteen minutes without the need for soldering, offering a unique blend of modularity and customization in the handheld gaming market.The handheld gaming sector features a variety of designs, but many share similar internal components. Beth Les project stands out by enabling extensive personalization through the use of Frameworks versatile mainboards, the design supports any 13-inch mainboard from Framework, including models with Intel, AMD, and RISC-V processors. This compatibility ensures that users can upgrade their devices as new mainboards are released, enhancing the longevity and adaptability of the handheld system.Beth Deck Internals Exposed. Photo via Beth Le.Assembly involves ten 3D print parts and a comprehensive parts list, which includes screws, heat set inserts, a gaming controller, USB-C dongles, an 8-inch touchscreen, and various cables. The additional components cost around $150, excluding the Framework mainboard and 3D printing filament. Beth emphasizes the projects accessibility: The whole thing can be assembled in about 15 minutes and disassembled in less than 2 minutes with no soldering, and all non-printed parts can be purchased. This ease of assembly makes the handheld an attractive option for DIY enthusiasts seeking a customizable gaming experience.Integrating a Framework 13-inch mainboard and battery with a 3D printed shell, the handheld features an 8-inch 800p touchscreen and a repurposed mobile gaming controller. However, using laptop components introduces certain limitations. Overheating has been identified as a potential issue due to limited airflow, and the absence of fan controls typical in dedicated handhelds may impact performance. Beth plans to address these concerns in Revision 2 of the project, which will feature a thinner design, a custom PCB for controls, and improved speakers.The cost of high-end mainboards, such as the 7840U priced at $699, may also deter some users. Despite these challenges, the project is praised for its innovative use of modular components and the potential for future upgrades, aligning with sustainable practices by extending the lifespan of existing hardware.The Beth Deck (white) next to a Valve Steam Deck. Photo via Beth Le.Open-Source Innovations in 3D PrintingMrblindguardian, a blind Reddit user, pioneered an AI-based workflow that enables the design and 3D printing of custom models without visual input. Using ChatGPT to generate descriptive feedback and Luma AI to create initial designs from text inputs, Mrblindguardian successfully produced a one-winged dragon model on a Bambu Lab X1 3D printer. The process involved iterative refinements where ChatGPT provided descriptions of the 3D model based on screenshots from Luma AI, allowing Mrblindguardian to adjust the design accordingly. This method required collaboration with a sighted friend to verify the final model before printing.Similarly, Ken Pillonels development of 3D printed, open-source USB-C cases for AirPods. By providing a repairable case that adds USB-C functionality to older models, Pillonel addresses e-waste and supports the right-to-repair movement. His use of selective laser sintering (SLS) technology demonstrates how 3D printing can produce precise, functional components without the need for large-scale manufacturing resources.Upgrading a standard AirPods case with a 3D-printed USB-C module, offering a sustainable solution for Apples planned obsolescence. Photo via Exploring the Simulation.Your voice matters in the 2024 3D Printing Industry Awards. Vote Now!What will the future of 3D printing look like?Which recent trends are driving the 3D printing industry, as highlighted by experts?Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.Stay connected with the latest in 3D printing by following us on Twitter and Facebook, and dont forget to subscribe to the 3D Printing Industry YouTube channel for more exclusive content.Featured images showcase the Beth Deck Internals Exposed and the Beth Deck next to a Valve Steam Deck. Photos via Beth Le.