A research team at the University of Arkansas has demonstrated that molecular dynamics (MD) simulations can reveal key mechanisms behind silicon nanoparticle crystallization during laser-induced forward transfer (LIFT) printing. The findings are detailed in a non-peer-reviewed preprint available on arXiv, where the authors show how nanoparticle size and cooling rate affect the ability of silicon to solidify into single-crystalline structures during flight, a development with potential implications for additive manufacturing of optoelectronic materials. Molecular-level insight into LIFT printing Laser-induced forward transfer (LIFT) is a promising technique for direct-write micro- and nanoscale printing of functional materials. Unlike conventional additive manufacturing processes that build parts layer by layer, LIFT uses a pulsed laser to eject material droplets from a donor film, enabling high-resolution patterning of metals, polymers, and semiconductors. While LIFT has been applied to amorphous silicon printing, the atomic-level dynamics of silicon crystallization during droplet flight remain poorly understood. To address this, researchers Youwen Liang and Wan Shou used MD simulations to analyze how size and thermal conditions influence silicon nanoparticle behavior during solidification. Simulated crystallization of silicon nanoparticles during LIFT printing. Image via Liang & Shou. Size and cooling rate determine crystal structure The simulations revealed a strong correlation between nanoparticle diameter and crystallization potential. Particles smaller than 4 nm failed to crystallize, even under slow cooling conditions, while larger particles (8–12 nm) exhibited latent heat release and structural ordering, key signatures of crystallization. The study also found that slow cooling rates are essential to promote crystallization. At higher cooling rates, supercooling effects dominated, resulting in amorphous structures. Under controlled thermal conditions, the researchers observed the formation of single-crystal-like silicon nanoparticles, with nucleation beginning just beneath the particle’s surface. The authors suggest that single-crystal formation in-flight is achievable, provided that droplet size and cooling rate are carefully controlled, a finding that may inform future single-crystal silicon additive manufacturing.Crystallization begins beneath the surface A key finding is that crystallization rarely initiates at the particle surface. Instead, nucleation typically begins ~5 Å beneath the outer layer, within what the researchers describe as a structurally distinct sub-surface region. These early nuclei then migrate toward the particle center, where crystal growth accelerates. Simulations also showed that surface atoms remain more mobile and disordered, even at low temperatures. Using bond order parameters (BOP), radial distribution functions (RDF), coordination numbers, and mean square displacement (MSD), the researchers tracked the atomic structure evolution throughout solidification. Comparison of atomic structures from MD simulations. Image via Liang & Shou. Towards single-crystal 3D printing The ability to predict and control crystallization at the nanoscale opens new possibilities for high-performance printed electronics, where grain boundaries can reduce efficiency and durability. By adjusting droplet size and cooling profiles, LIFT could eventually enable on-demand printing of single-crystal semiconductors, bypassing traditional lithography or epitaxy methods. While the current results are based on simulations, they provide a foundational framework for experimental validation and future process optimization in nanoscale additive manufacturing.Crystallization Control in Additive Manufacturing Achieving precise control over crystallization during additive manufacturing is pivotal for enhancing material properties and performance. In polymer-based 3D printing, researchers from the Air Force Research Laboratory, Cornell University, and Boeing have successfully mapped the crystallization process of poly(ether ether ketone) (PEEK) during fused filament fabrication. Utilizing synchrotron-based microbeam wide-angle X-ray scattering (WAXS), they provided a detailed 2D map of PEEK crystallization process in the initial seconds post-extrusion. This study revealed that higher print bed temperatures delay the onset of crystallization but result in a higher final degree of crystallinity, thereby enhancing the mechanical properties of the printed parts. In metal additive manufacturing, researchers in Japan demonstrated the fabrication of single-crystal nickel using selective laser melting (SLM). By optimizing laser parameters and using a flat-top beam profile, they achieved homogenous, single-crystal structures without a pre-existing seed, a breakthrough with potential for high-temperature aerospace components such as turbine blades.These studies highlight the central role of thermal management and process design in crystallization control. The current MD simulation of silicon nanoparticle solidification during LIFT builds upon this foundation, offering atomic-level insights into nucleation and growth. Such fundamental understanding is essential to push the boundaries of precision-engineered, crystallinity-controlled 3D printed materials. Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news. You can also follow us onLinkedIn and subscribe to the 3D Printing Industry YouTube channel to access more exclusive content. At 3DPI, our mission is to deliver high-quality journalism, technical insight, and industry intelligence to professionals across the AM ecosystem. Help us shape the future of 3D printing industry news with our2025 reader survey. Feature Image shows comparison of atomic structures from MD simulations. Image via Liang & Shou.

Metal additive manufacturing (AM) is expected to reach a market value of $13 billion by 2035, nearly tripling in size over the next decade, according to a new report from IDTechEx. The report, Metal Additive Manufacturing 2025–2035: Technologies, Players, and Market Outlook, outlines how metal AM is shifting from prototyping and tooling to end-use production in sectors such as aerospace, automotive, and general manufacturing. IDTechEx, an independent research firm focused on emerging technologies since 1999, identifies three key trends currently shaping the metal AM market: the dominance of laser powder bed fusion (LPBF), regional acceleration in China, and the economic uncertainty driven by tariff policies. Laser Powder Bed Fusion Retains Market Leadership Due to Versatility and Maturity Despite rising interest in alternative technologies like metal binder jetting (MBJ) and metal-polymer filament extrusion (MPFE), LPBF continues to dominate metal AM in both revenue and adoption. LPBF, which uses lasers to fuse metal powder into parts layer by layer, is the most commercially mature metal 3D printing method. It is backed by extensive operational experience from both equipment manufacturers and industrial users. MBJ and MPFE were expected to challenge LPBF due to their simplified workflows and potential cost advantages. However, IDTechEx reports that end-users are still grappling with technical and economic limitations in these newer methods. For example, MBJ is limited by sintering constraints, making it suitable only for specific geometries and part sizes, while MPFE is often confined to prototyping, jigs, and fixtures due to material and strength limitations. LPBF’s strength lies in its ability to scale across a wide range of applications. Depending on machine configuration—such as build volume or number of lasers—LPBF systems are used for producing small injection molds and large aerospace components alike. This range of use cases reinforces LPBF’s position as the leading technology in the metal AM sector. Breakdown of the 2024 global metal AM install base by process. Image via IDTechEx. Domestic Growth in China Redefines Global Market Share Metal AM in China is expanding rapidly, supported by a domestic ecosystem that prefers cost-competitive local manufacturers. Companies such as Xi’an Bright Laser Technologies (BLT), HBD, and EPlus3D have significantly increased their market presence over the past decade, supplying Chinese firms across sectors including aerospace and automotive. These manufacturers have grown without heavily relying on exports. While international attention to Chinese metal AM remained low until recent years, domestic demand has allowed firms like BLT to scale consistently. Double-digit annual growth rates have enabled several of these companies to open offices in Europe and North America, establishing new distribution partnerships and service networks. Price remains a key selling point. Metal AM systems require high upfront capital, and the affordability of Chinese-built machines is a primary factor for international customers evaluating suppliers. However, IDTechEx notes that escalating trade tensions and the introduction of new tariffs could complicate overseas expansion plans for Chinese firms. Even so, the scale of China’s internal market is expected to sustain ongoing development in the region. Tariff Pressures Generate Mixed Signals for Investment in Additive Manufacturing Tariff policies designed to promote domestic manufacturing in the United States are producing conflicting effects for the metal AM industry. On one side, tariffs have prompted renewed interest in reshoring and local production. This shift could favor metal AM technologies that enable decentralized manufacturing and rapid lead times. However, uncertainty surrounding tariffs has already triggered a pullback in capital spending across several industries. Companies are delaying investments in new manufacturing facilities, and many are scaling back research and development budgets. These developments affect the willingness of firms to adopt emerging production technologies like metal AM, particularly for applications that require substantial upfront validation and certification. IDTechEx reports that in the second half of 2024, economic uncertainty contributed to a slowdown in metal AM growth. The report suggests that this trend could continue depending on how trade and industrial policy evolve in 2025. Forecast from IDTechEx showing projected growth of the metal additive manufacturing hardware and materials market from 2025 to 2035, with a compound annual growth rate (CAGR) of 10.4%. Image via IDTechEx. Market Projections Segmented by Technology and Material Class The report provides detailed forecasts for metal AM hardware, materials, and installed base growth through 2035. Projections are broken down into ten metal printing processes and nine categories of metal materials, offering granular insight into market dynamics. Forecast data is supplemented with comparative benchmarks for each technology and application case studies. Material demand is also expected to rise as metal AM transitions to production-scale use. The report highlights increasing requirements for powder uniformity, process stability, and repeatable part quality—factors critical for certification in aerospace and other high-regulation sectors. Profiles of leading companies are based on direct interviews and market performance tracking. These include manufacturers of LPBF systems, providers of MBJ technologies, and developers of metal feedstocks. The analysis also outlines competitive strategies and regional positioning. Access to Full Research and Industry Insights The full Metal Additive Manufacturing 2025–2035 report is available at www.IDTechEx.com/MetalAM, where sample pages and additional data are also offered. IDTechEx’s broader 3D printing research portfolio includes coverage of polymers, ceramics, electronics, and large-scale applications such as construction and biomedical devices. To view the full library of additive manufacturing market studies, visit www.IDTechEx.com/Research/3D. Cover of Metal Additive Manufacturing 2025–2035: Technologies, Players, and Market Outlook. Image via IDTechEx. Ready to discover who won the 20243D Printing Industry Awards? Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights. Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. Featured image shows the cover of Metal Additive Manufacturing 2025–2035. Image via IDTechEx. Anyer Tenorio Lara Anyer Tenorio Lara is an emerging tech journalist passionate about uncovering the latest advances in technology and innovation. With a sharp eye for detail and a talent for storytelling, Anyer has quickly made a name for himself in the tech community. Anyer's articles aim to make complex subjects accessible and engaging for a broad audience. In addition to his writing, Anyer enjoys participating in industry events and discussions, eager to learn and share knowledge in the dynamic world of technology.

Every maker knows that familiar frustration: you’re deep into a project, carefully crafting something amazing, when your cutting tool snags, slips, or simply can’t handle the precision you need. Traditional cutting methods often leave rough edges, melted plastic, or splintered materials that require hours of additional sanding and finishing. Whether you’re trimming 3D prints, working with delicate materials, or adding intricate details to a model, the limitations of conventional tools can turn creative excitement into tedious damage control. The NeoBlade wireless ultrasonic cutter changes everything about how makers approach precision cutting tasks. This revolutionary tool harnesses the power of 40 kHz ultrasonic vibration technology in a compact, cordless package that weighs just 6.4 ounces with the battery installed. The high-frequency micro-vibrations allow the blade to slice through materials with minimal pressure and maximum control, creating the sensation of cutting through butter even when working with tough materials like carbon fiber, acrylics, or dense woods. This game-changing approach eliminates the struggle and frustration that often accompany detailed cutting work. Designer: HOZO Design Click Here to Buy Now: $99 $149 (33% off). Hurry, only 48/300 left! Raised over $216,000. What truly sets the NeoBlade apart is its intelligent auto power adjustment system that intuitively adapts to different materials as you cut. This smart technology means you don’t need to constantly fiddle with settings or worry about applying too much force when transitioning between materials in mixed-media projects. The cutter automatically optimizes its performance whether you’re working with delicate PLA filament from a 3D print, tough ABS plastic, natural wood, or even PCB boards, allowing you to focus entirely on your creative vision rather than managing your tool. Dual cutting modes provide versatility for different project needs without compromising on performance. Precision mode delivers short, controlled cuts perfect for trimming intricate details, deburring edges, or making tiny adjustments to delicate parts. When you need to make longer cuts for splitting materials or creating grooves, Continuous mode keeps the blade vibrating without interruption, allowing smooth, consistent cutting action across the entire length of your workpiece. It’s a kind of flexibility that makes the NeoBlade suitable for everything from quick touch-ups to major fabrication tasks. Heat management has always been the Achilles’ heel of cutting tools, but the NeoBlade’s built-in turbofan cooling system solves this problem elegantly. The innovative ventilation design pulls air through side vents to maintain optimal operating temperature even during extended use. This cooling technology not only prevents the blade from overheating but also keeps the handle comfortable in your hand during long work sessions. More importantly, it ensures consistently clean cuts without the melted edges or material distortion that often occurs with overheated cutting tools. The versatility of the NeoBlade expands dramatically with its six interchangeable blade options, each designed for specific cutting challenges. The standard 30-degree edge handles most everyday tasks, while specialized options like the curved blade for fluid motions, the chisel-like blade for carving, and the double-edge blade for creating precise grooves allow you to tackle virtually any cutting task with confidence. Each blade comes in a spring-loaded dispenser with a one-way disposal slot, making replacements quick, easy, and safe without interrupting your creative flow. Changing the Battery Battery management becomes virtually effortless with the TurboDock charging system, eliminating the productivity-killing downtime that plagues other wireless tools. The dual-slot dock simultaneously charges both the NeoBlade and a spare battery in just 30 minutes, ensuring you always have power ready when inspiration strikes. This quick-swap battery system means you can work continuously on large projects without frustrating interruptions, maintaining your creative momentum from start to finish without being tethered to a power outlet or waiting for recharging. For serious makers who understand that the right tools transform not just the final product but the entire creative process, the NeoBlade represents a significant evolution in cutting technology. Its combination of wireless freedom, intelligent power management, and ultrasonic precision opens new possibilities for projects that previously seemed too delicate or complex to attempt. By removing the limitations and frustrations of traditional cutting methods, the NeoBlade doesn’t just help you make things; it fundamentally changes how you approach the making process, freeing your creativity to explore new materials, techniques, and designs without compromise. Click Here to Buy Now: $99 $149 (33% off). Hurry, only 48/300 left! Raised over $216,000.The post NeoBlade: World’s Smallest Wireless Ultrasonic Cutter Revolutionizes DIY Projects first appeared on Yanko Design.

Photo Credit: NASA / SDO and the AIA, EVE, and HMI science teams, helioviewer.org Solar filament erupts as dark ribbon from sun’s upper right Highlights A massive 600,000-mile-long solar filament erupts from the sun’s surface Fiery filament blast triggers a stunning coronal mass ejection into space “Angel-wing” eruption mesmerizes skywatchers with its vast visual scale Advertisement A stunning solar eruption captured on video on the night of May 12-13 has revealed a 600,000-mile-long filament blasting away from the sun's northern hemisphere. The outburst occurred around 8 p.m. EDT (0000 GMT) and spanned a distance more than twice that between Earth and the moon. A massive solar filament suspended above the sun's surface became unstable and erupted, blasting a CME into space along with a cloud of plasma and magnetic energy. Preliminary models show Earth is nowhere in the firing range of this fiery ejection, but researchers are still watching the phenomenon closely.Sun's 600,000-Mile-Long ‘Angel-Wing' Eruption Stuns Skywatchers, Signals Rising Solar ActivityAs per the Space.com report, the eruption originated from a filament structure composed of dense, cooler solar plasma held aloft by magnetic fields. These structures often appear as dark ribbons across the sun's disk and can become unstable without warning. Solar observers noted that this latest eruption dwarfed similar recent events, both in scale and intensity. Aurora chaser Jure Atanackov remarked that the CME from the blast was among the most spectacular seen this year, although fortunately, it is headed north and will miss Earth.The event, dubbed the “angel-wing” or “bird-wing” eruption by observers online, was widely shared among solar watchers. Vincent Ledvina, another aurora chaser, noted its incredible visual impact, describing it as a sight worth watching on loop. The eruption is, in fact, so long, by more than a million kilometres, that it is of scientific interest and visually striking as well. Geomagnetic storms resulting from this kind of CME can affect satellites, communication systems, and even Earth.Although it foreshadows the unpredictable nature of our host star, this particular CME does not pose a threat to Earth at the moment. Solar activity is ramping up as we approach the peak of Solar Cycle 25 in 2025. What's more, more — and maybe more Earth-threatening — solar explosions could follow.As a reminder of the formidable and delicate forces at play relatively close by on Earth, the sun remains a source of wonder for astronomers and skywatchers alike. For the latest tech news and reviews, follow Gadgets 360 on X, Facebook, WhatsApp, Threads and Google News. For the latest videos on gadgets and tech, subscribe to our YouTube channel. If you want to know everything about top influencers, follow our in-house Who'sThat360 on Instagram and YouTube. Further reading: sun eruption, solar filament, coronal mass ejection, CME, solar flare, sun activity, space weather, astronomy Gadgets 360 Staff The resident bot. If you email me, a human will respond. More

Chinese 3D printing technology firm SUNLU has released a new filament drying system designed to offer more flexibility for 3D printing users managing multiple spools.  Called the FilaDryer SP2, the unit separates its heating base from the drying chambers, allowing up to three chambers to be stacked vertically. This setup is aimed at users running several printers at once, where space is limited and filament drying often becomes a bottleneck. Founded in 2013 in Zhuhai, China, SUNLU specializes in 3D printing materials and hardware, with a product range that includes filaments, resins, and accessories. Having sold more than 25 million units, the company runs over 140 production lines and holds over 200 granted IP rights related to materials and equipment design. FilaDryer SP2 Capacity. Image via Sunlu. Scalable design with efficient drying One of the key goals behind the SP2 is to improve drying efficiency. In repeated tests with PETG, the system brought moisture levels down from 0.6% to 0.2% in just four hours. That’s around 30% faster than other dryers in the same category. The adjustable temperature range, which runs from 35°C to 70°C, makes it suitable for common materials like PLA as well as moisture-sensitive filaments such as nylon.  Each chamber includes a built-in humidity sensor for real-time monitoring and offers enough space to hold either two 1kg spools, a single 2–3kg spool, or spools measuring up to 250 mm in diameter and 153 mm in width. The generous capacity is especially useful during long print jobs, where smaller dryers often fall short. In one example, saturated PLA reached optimal moisture levels within four to six hours at 55°C, demonstrating the system’s effectiveness for extended use cases. Safety features are built into the SP2’s design. It uses a ceramic PTC heater combined with a smart fan to ensure heat is evenly distributed. A mechanical cutoff switch activates if temperatures spike unexpectedly, while a PID-controlled microprocessor keeps the system stable within a one-degree range.  The device has passed 72-hour continuous operation tests and was also run through high-stress scenarios to confirm reliability. Additional silicone gaskets at connection points help keep moisture out and maintain consistent drying conditions. Compared to conventional dryers, which are typically fixed in design and limited to a single chamber, the SP2 offers a more scalable solution. Instead of purchasing an entirely new unit, users can expand capacity by adding additional chambers. It also accommodates smaller spools without the need for adapters or modifications.  Additionally, internal testing indicates up to 35% lower energy consumption than similar products. In early use, the system has also been noted for its quiet operation at 42dB, stable stacking, and consistent temperature control across extended sessions. Dry and store filaments with built-in heating and humidity control. Image via Sunlu. Technical specifications and pricing For pricing details and more information, readers can visit Sunlu’s website. Product NameSUNLU Filament Dryer SP2 / Storage Box SetProduct Dimension278mm × 208mm × 396mm (L x W x H)Internal Dimensions265mm × 193mm × 274mm (L x W x H)Package Size337mm × 263mm × 380mm (L x W x H)N.W.FilaDryer SP2 Set: 3.6KG, Storage Box Set: 5.0KGG.W.FilaDryer SP2 Set: 4.1KG, Storage Box Set: 5.5KGOperating EnvironmentTemperature: 10°C-35°C, Relative Humidity: ≤95%Compatible Filament DiametersΦ1.75mm/Φ2.85mmMaximum Spool SizeΦ250mm × 153mm (1kg × 2 or 2kg × 1 or 3kg × 1)Work Temperature Range35°C-70°C (PLA, PLA+, PETG, ABS, TPU, PVA, PVB, ASA, PA/PC etc.)Humidity Display RangeRefer to the Hygrometer: 10%-90%Time Setting Range0-99hPower Input Specifications(Ensure the voltage matches your local supply before use)AC 110V 60Hz 0r AC 220V 50HzMaximum Operating Current2.2A@230V, 4.2A@120VMaximum Working Power250wStand by Power≤1WPackage Contents: FilaDryer SP2 SetStorage Box *1, Heating Base *1, Hygrometer *1, Desiccant *1, Desiccant Box *1, Power Cable *1, Spool Roller *1, Air lock *2, PTFE Tube 8cm *2, PTFE Tube 1m *2, User Manual *1Storage Box SetStorage Box *1, PLA+2.0 Black *2, Hygrometer *1, Desiccant *1, Desiccant Box *1, Spool Roller *1, Air lock *2, PTFE Tube 8cm *2, PTFE Tube 1m *2, User Manual *1 Take the 3DPI Reader Survey — shape the future of AM reporting in under 5 minutes. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Twitter, or like our page on Facebook. While you’re here, why not subscribe to our Youtube channel? Featuring discussion, debriefs, video shorts, and webinar replays. Featured image shows the Sunlu FilaDryer SP2. Image via Sunlu. Ada Shaikhnag With a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

The transition from teal to pink is so elegant.

The transition from teal to pink is so elegant.

Molex, global manufacturer of electronic and fiber optic connectivity systems, is working with Czech FDM 3D printer manufacturer Prusa Research to support the integration of connector technologies into 3D printing systems. Key components in this collaboration include Molex’s CLIK-Mate wire-to-board connectors, Micro-Fit power connectors, and ultra-microcoaxial RF connectors.  With support from American multinational electronics components distributor Arrow Electronics, these systems are designed to streamline assembly processes and simplify upgrades and new product introductions. “Prusa Research needed connectivity systems with the right balance of functionality and simplicity without compromising quality,” said Brian Hauge, SVP and president, Consumer and Commercial Solutions, Molex. “With support from Arrow Electronics, we provide a full portfolio of connectors that are robust yet easy to use. Molex also stays in lockstep with Arrow and Prusa engineers to align emerging printer designs with new innovative connector solutions to ease new product introductions and upgrades.” The Original Prusa MK4 printing a component. Photo via Prusa Research. Prusa: Scaling Operations to Meet Global Demand In 2024, Prusa Research processed over 300,000 orders for printers, filaments, resins, and accessories. To further strengthen its global presence, the company also established a U.S. subsidiary, Printed Solid, in Newark, Delaware, focused on producing printers and filaments within the United States. As part of its ongoing expansion, Prusa Research incorporated Molex connector systems into its manufacturing process. The CLIK-Mate connectors were selected for their low insertion force, secure terminal design, and audible engagement feature, ensuring precise installation. Prusa highlighted that CLIK-Mate connectors not only ensure DIY users avoid incorrect connections, but also assist engineers in enhancing production efficiency by accelerating the surface mount technology (SMT) assembly process. By early 2025, Prusa is utilizing up to 16 variations of CLIK-Mate connectors across its printer lineup, including the newly launched CORE One model. “In 2024, Prusa grew 25% year over year, and we are excited for this year, which will be even bigger,” said Josef Prusa, CEO of Prusa Research. “We populated over one million parts using Molex CLIK-Mate connectors last year, and they’ve all delivered excellent performance. With over 20 printer models using Molex connectors, we’re continuing our collaboration with Arrow and Molex to expand further across Europe and scale our U.S. operations.” Additional Molex systems used by Prusa include Micro-Fit Connectors for combining signal and power in constrained spaces, and ultra-microcoaxial RF connectors for Bluetooth and Wi-Fi connections. The company is also evaluating Molex’s Easy-On FFC/FPC connectors and other customized connectivity solutions for potential implementation in future models. Prusa Research’s Expanding Lineup Prusa Research continues to evolve its 3D printer portfolio to meet the needs of both professional and advanced desktop users.  One of Prusa’s latest innovations is the Prusa XL, featuring a CoreXY configuration and a 360 mm³ print volume. This model stands out with its tool changer that includes five independent toolheads, reducing waste compared to single-nozzle alternatives and offering increased versatility. While the Prusa XL may not be the fastest desktop FFF 3D printer, with a maximum 3D print speed of 400 mm/s, its ability to seamlessly switch between toolheads for different nozzle sizes and filament types enhances productivity, especially for multi-material parts. The fully assembled version of the Prusa XL is priced at €2,599, while the semi-assembled model is available for €2,099 on the official Prusa website. Additionally, Prusa’s professional-grade offerings include the Prusa Pro HT90, a delta-kinematics 3D printer designed for high-speed, high-temperature FDM printing. The Prusa Pro HT90 delivers impressive performance with travel speeds of up to 600 mm/s, 3D print speeds of 250 mm/s, and acceleration rates of 20,000 mm/s². The system features lightweight, quick-swap printheads, with a direct-drive extruder to enhance production efficiency. Its High-Temp printhead can reach temperatures up to 500°C, suitable for challenging materials, while the High-Flow head operates best at 300°C, enabling the printer to deposit 1 kg of PETG or ABS in just 8 hours. The Prusa Pro HT90 is available starting at €11,490. Take the 3DPIReader Survey — shape the future of AM reporting in under 5 minutes. Who won the 2024 3D Printing Industry Awards? Subscribe to the3D Printing Industry newsletter to keep up with the latest 3D printing news. You can also follow us on LinkedIn, and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content. Featured image shows the new Prusa Core One. Photo via Prusa Research.

A team led by researchers at the University of Illinois Chicago and UC Davis has developed a method to 3D bioprint tissue-specific, high cell-density bioinks capable of forming complex multiphase constructs. Published in Materials Today, the study introduces a platform that combines individual or aggregate-based stem cell bioinks with localized growth factor delivery, offering precise control over spatial differentiation and tissue development. Using a shear-thinning, photocrosslinkable alginate microgel supporting bath, the research team successfully printed structures with high shape fidelity and tunable degradation. These constructs enable self-assembly through cellular condensation and localized differentiation into distinct tissues such as cartilage and bone. After four weeks of culture, the bioprinted structures maintained their original geometry and exhibited clear phase separation between chondrogenic and osteogenic regions. A new approach to bioink precision Conventional bioprinting approaches often rely on biomaterial-laden inks that can interfere with direct cell–cell interactions and degrade unpredictably. To overcome these limitations, the researchers developed bioinks containing either individual stem cells or multicellular aggregates, combined with gelatin microparticles (GMs) loaded with growth factors such as TGF-β1 and BMP-2.These formulations demonstrated favorable rheological properties, shear-thinning, self-healing, and low yield stress, making them well-suited for extrusion-based bioprinting. Critically, the growth factor-loaded GMs allowed for spatially controlled, sustained biochemical signaling without requiring external supplementation.Following 3D printing and stabilization of the supporting bath, stem cells underwent lineage-specific differentiation, resulting in stable osteochondral constructs. Histological and biochemical analyses confirmed targeted extracellular matrix deposition and distinct tissue boundaries at the cartilage–bone interface.3D printing of the tissue specific high cell-density bioinks within the OMA microgel supporting bath, which fluidizes via its shear-thinning property. When the printing needle fluidizes the mechanical stable OMA microgels (i, disordered region), tissue specific high cell-density bioinks can fill the shear-thinning region (ii). After the needle passes, the OMA microgel bath can be stabilized by its self-healing property (iii, self-healing region) to firmly hold the printed bioinks. Image via Jeon et al., Materials Today. From biomaterials to biofunction While 3D bioprinting has long promised the recreation of complex biological architectures, printing functional, multicellular, multi-tissue constructs remains a key challenge. Cell-only bioinks often require preformed strands or aggregates, limiting resolution and design flexibility. The approach developed by Jeon et al. addresses this gap, enabling high-resolution deposition of cell-dense bioinks that self-organize into biologically relevant structures. Characterization of resolution and shape fidelity and chondrogenic differentiation of 3D bioprinted constructs. (A) Photomicrographs of the 3D printed individual cell-based tissue specific bioink filaments [i and ii; TGF-β1-loaded GM + hMSCs. iii and iv; bone morphogenic protein-2 (BMP-2)-loaded GM + hASCs] into OMA microgel supporting baths with a 22G printing needle and (B) quantification of their mean diameters, demonstrating the capability of high-resolution printing with narrow filament diameter distribution. Scale bars indicate 500 μm. N.S.: Not significant. (C) Digital images and (D) photographs of the 3D printed structures, demonstrating high shape fidelity. The scale bars indicate 5 mm. (E) Photomicrographs of Saf-O/Fast Green stained construct sections cultured in BPM (i and ii) and CPM (iii and iv). The scale bars indicate 500 μm. (F) Quantification of GAG/DNA in the chondrogenically differentiated 3D printed constructs. These demonstrate hMSC differentiation and deposition of chondrogenic extracellular matrix (ECM) in the individual cell-based tissue specific bioink printed constructs. N.S.: Not significant. Image via Jeon et al., Materials Today. Recent innovations have similarly advanced bioink design and tissue engineering. Researchers at Seoul National University of Science and Technology, developed a  SCOBY-derived bioink to 3D print cellulose scaffolds for direct tissue repair, while another team created a personalized heart-on-a-chip using photopolymerizable, patient-specific bioinks. Bio INX and Readily3D launched a ready-to-use bioink for volumetric bioprinting, and Texas A&M engineered a specialized vascular-specific bioink tailored for blood vessel formation. Elsewhere, studies have demonstrated functional brain tissue constructs with active neural networks, and Frontier Bio received a 2024 3DPI Award for developing lung-like tissue in vitro. Jeon et al.’s work builds on these efforts by integrating localized growth factor delivery into high cell-density bioinks, enabling the fabrication of multiphase tissues with fine spatial control and biological fidelity.By controlling the spatial presentation of bioactive cues within densely cellular environments, the platform holds promise for regenerative medicine, disease modeling, and drug screening. Future research will aim to enhance tissue maturation and incorporate vascularization to improve functionality and translational potential. What 3D printing trends should you watch out for in 2025? How is the future of 3D printing shaping up? Subscribe to the 3D Printing Industry newsletter to keep up with the latest 3D printing news.You can also follow us onLinkedIn and subscribe to the 3D Printing Industry Youtube channel to access more exclusive content.