Advancements in Additive Manufacturing

🪄 3D printing just broke free from gravity — and it happened at Disneyland Paris. Coperni, in collaboration with Disney Research, showcased a revolutionary technique called Rapid Liquid Printing (RLP) — a gel-based 3D printing process that allows objects to form freely in liquid space. The innovation: Instead of building layer by layer, RLP prints directly inside a gel bath. The gel supports the structure as it forms, meaning objects can be “drawn” in mid-air with smooth, continuous motion. What’s new: • No gravity constraints — objects print in all directions. • No supports or post-processing needed — a simple rinse finishes the product. • Compatible with soft materials like silicone and rubber, enabling flexibility and realism. Why it matters: This breakthrough eliminates one of 3D printing’s biggest limitations — the need for support structures. It drastically speeds up production, reduces waste, and enables designs that were previously impossible. → Fashion and luxury design — complex, fluid shapes in textiles and accessories → Architecture and furniture — organic, continuous forms without assembly → Healthcare and robotics — flexible components mimicking natural motion To me, this represents the next era of creation — where 3D printing stops stacking layers and starts shaping ideas in real time. Could this be the moment 3D printing becomes as intuitive as sketching in air? #3DPrinting #Design #Manufacturing #Creativity #FutureOfWork #Engineering #ArtAndTech

𝐓𝐡𝐞 𝐢𝐝𝐞𝐚 𝐨𝐟 𝟑𝐃 𝐩𝐫𝐢𝐧𝐭𝐢𝐧𝐠 𝐡𝐚𝐬 𝐣𝐮𝐬𝐭 𝐛𝐞𝐞𝐧 𝐟𝐥𝐢𝐩𝐩𝐞𝐝 𝐨𝐧 𝐢𝐭𝐬 𝐡𝐞𝐚𝐝. Instead of printing metal, a team of scientists in Switzerland grew it from a gel – and the result is 20x stronger than previous methods. Using a water-based hydrogel as a scaffold, researchers at EPFL (École Polytechnique Fédérale de Lausanne) created complex structures that can be infused with metal salts. After several rounds of soaking and heating, the gel vanishes – leaving behind dense, ultra-strong metal or ceramic. Traditional metal 3D printing often results in porous structures with serious shrinkage. This new method dramatically reduces those flaws, producing durable, precisely shaped components with only 20% shrinkage. It also opens the door to building with a wide range of materials – the same gel template can be used to grow iron, silver, copper, or even advanced composites. The technique could revolutionize how we make complex, high-performance parts for energy systems, biomedical devices, and next-gen electronics. It’s also a shift in mindset: rather than designing around the limits of printing materials, this approach lets researchers build first, and choose the material later. The team is already working on automating the process, aiming to bring this breakthrough into real-world manufacturing. Read the study "𝐻𝑦𝑑𝑟𝑜𝑔𝑒𝑙‐𝐵𝑎𝑠𝑒𝑑 𝑉𝑎𝑡 𝑃ℎ𝑜𝑡𝑜𝑝𝑜𝑙𝑦𝑚𝑒𝑟𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝐶𝑒𝑟𝑎𝑚𝑖𝑐𝑠 𝑎𝑛𝑑 𝑀𝑒𝑡𝑎𝑙𝑠 𝑤𝑖𝑡ℎ 𝐿𝑜𝑤 𝑆ℎ𝑟𝑖𝑛𝑘𝑎𝑔𝑒𝑠 𝑣𝑖𝑎 𝑅𝑒𝑝𝑒𝑎𝑡𝑒𝑑 𝐼𝑛𝑓𝑢𝑠𝑖𝑜𝑛 𝑃𝑟𝑒𝑐𝑖𝑝𝑖𝑡𝑎𝑡𝑖𝑜𝑛." 𝐴𝑑𝑣𝑎𝑛𝑐𝑒𝑑 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠, 2025 https://lnkd.in/eian6kVx

How Butterflies help us to transform Sewage Sludge into Next-Gen 3D Printing Materials Every year, millions of dry metric tons of sewage sludge, an organic-rich byproduct of wastewater treatment, pose a huge disposal challenge and environmental burden. Traditionally destined for incineration, landfills, or limited agricultural use, this overlooked resource is now getting a second life through innovative material science! We developed a method to harness hydrothermal processing (HTP) to convert wet sewage sludge into hydrochar, carbonaceous solid that can be further activated. Unlike typical biomass, sewage sludge contains unique metallic and metalloid dopants. These impurities lead to surprising outcomes during thermal activation: instead of the expected boost in carbon content and improved graphitic ordering, the process actually decreases carbon ordering, creating a distinct material structure with its own set of properties. When incorporated into 3D printing resins, this hydrochar acts as a sustainable filler. Initially, it may compromise stiffness and hardness due to limited resin-filler adhesion. However, by adopting nature-inspired gyroid geometries, designs reminiscent of butterfly wings and bird feathers, the composite’s toughness and elongation can not only be recovered but enhanced! This integration of bio-inspired architecture overcomes inherent material weaknesses and paves the way for eco-friendly prototypes, packaging, and beyond. 1️⃣ Diverting millions of tons of sludge from landfills and incineration reduces greenhouse gas emissions and pollutant dispersion. 2️⃣ Incorporating waste-derived hydrochar in 3D printing reduces reliance on raw synthetic materials, promoting a circular economy and sustainable manufacturing. 3️⃣ The synergy between material science and bio-inspired design opens new horizons for advanced composites with tailored properties through innovative design. This fusion of waste valorization, unconventional chemistry, and cutting-edge design showcases a transformative path toward sustainable manufacturing. Read more details in the paper (open access): Sabrina Shen, Branden Spitzer, Damian Stefaniuk, Shengfei Zhou, Admir Masic, Markus J. Buehler, Communications Engineering, Vol. 4, 52 (2025), https://lnkd.in/eBeESHJY

🔄 Sometimes innovation takes unexpected paths! Automotive did a concept study in 2019 - bike industry makes a commercial viable product in 2024, while the idea behind is very similar: 2015-2019: A group of companies around EDAG Group active in the automotive industry developed the groundbreaking "NextGenSpaceframe" concept: • bionic-designed Additive Manufacturing nodes • glued together with Aluminum profiles • Flexible, tool-less manufacturing • proven in crash tests to withstand automotive demands • resulting in over 20% weight reduction and the ability to produce much more flexible cars. But despite its potential, the automotive industry hesitated to take the commercial risk and capacity for production at target costs have not been available at that time. 💡 Fast forward to 2024: The same concept is innovating the bike industry and was made commercial viable by Möve Mobility GmbH in Thuringia ! • 3D-printed titanium nodes • Oval titanium tubes • 6-bar structural adhesive injection joining technology to clue parts together instead of welding • Result: Ultra-light and more sustainable e-bike frames 🚲 Proof point: Bikes are up to sale. At rapid.tech3D, Eplus3D Additive Manufacturing showcased this premium e-bikes including a ~8 kg e-gravel bike demonstrating AM as a true enabler. Hats off, Chloe (Meike) Hünefeld and Möve team ! 🎩👏 🎯 My key learning: Advanced Manufacturing succeeds when combining clever design of unique AM parts with classical manufacturing technologies. And it needs innovative and courageous 💪 entrepreneurs to transform it into commercial success! Maybe it wasn't failure in automotive to not commercialize yet - just timing. Will the European automotive industry wake up and revisit these concepts? #AdditiveManufacturing #Automotive #3DPrinting Martin Hillebrecht EDAG Group Julian Waldmann Enis Jost Frank Beckmann Fraunhofer IAPT Siemens Digital Industries Software

Virtual reality is not just a tool for entertainment but a game-changer in product design, allowing teams to experiment, refine, and collaborate remotely in ways that were once impossible, leading to faster innovation, cost reductions, and more precise manufacturing outcomes. Immersive 3D environments are transforming product design by eliminating physical constraints and allowing real-time iteration. Virtual prototyping enables companies to test designs without manufacturing costly models, reducing waste and accelerating development. Interactive visualization helps engineers refine products before production, leading to better ergonomics and functionality. Remote collaboration means teams across continents can work seamlessly, breaking traditional logistical barriers. Realistic product previews enhance customer trust and decision-making, particularly in industries like architecture, automotive, and consumer electronics, where accurate representations are crucial for investments and sales. #VirtualReality #3DDesign #ProductDevelopment #RemoteCollaboration #DigitalTransformation

🚀 AI is revolutionizing prototyping—making it faster, smarter, and more sustainable. From my early work with Sony’s AIBO to advising AI startups today, I’ve seen firsthand how AI-generated prototypes are transforming industries. What once took months of manual iteration is now done in days with AI-driven design, 3D printing optimizations, and digital twins. 🌍 The impact? Lower costs, reduced waste, and smarter material usage. Companies like Airbus, BMW, and Adidas are already leveraging AI to cut material waste by up to 50% and reduce costs by over 70%. Startups can now test and refine products virtually before manufacturing a single physical model. This is not just about efficiency—it’s about sustainable innovation. AI is reshaping how we build, test, and bring ideas to life. Those who embrace it now will gain a massive competitive edge. Read my latest article on the rise of AI-generated prototypes and how they are changing the game 👇 #AI #Innovation #Sustainability #Prototyping #3DPrinting #DigitalTransformation #AIStartups #FutureOfTech

🚀 Are we witnessing the end of blocky 3D prints? Researchers at Johns Hopkins have developed AN3DP — an active nozzle that changes its shape and diameter mid-print! 🔥 Inspired by tendons and retractable grabber tools, it uses 8 movable pins and an elastic membrane to reshape on the fly. The result? 🔹 Higher precision 🔹 Faster printing 🔹 Large-scale prints with fine detail Applications? From aerospace to soft electronics to architectural structures. 👉 A breakthrough published in Science Advances — proof that FDM is evolving faster than ever.

METAL 3D PRINTING IS A DEFENSE TECHNOLOGY It is not exclusively this, but it is this to a very large extent. Reasons/observations: 1️⃣ Suppressors have become a standard component of military firearms. The suppressor is a fluid (gas) handling device. Formerly assembled through welding, it is one of those parts now made additively that will be made additively from here on out. It is hard to miss how much laser powder bed fusion capacity is currently being devoted to making suppressors. 2️⃣ The kinds of AM-enabled advances that have assisted the commercial space industry directly apply to guided weapons systems as well. 3️⃣ The Department of Defense has a practice and culture of supporting innovation via suppliers and contractors. Commercial business generally is not like this. A new idea for a commercial business either must be developed in-house, or it must arrive fully developed by the supplier. With the DoD, there is a funded innovation path allowing a technology set like AM to find its applications and advances through the work of various companies. 4️⃣ The military wants shorter and less complex supply chains. AM enables this through part consolidation and inventory replacement. To be sure, every manufacturing buyer wants shorter and simpler supply chains. But the military is most apt to pursue this because of its added need for supply chains that can function during times of disruption and challenged logistics. 5️⃣ Military production has to be (A) scalable within a short period of time while also (B) shelvable for a long period of time between conflicts. Additive is distinctively both. No tooling is needed to scale production – digital files can be sent to more machines. Meanwhile, the fully digital process means there is no tooling to become lost over time, and production is easy to resume even in a far future after the original suppliers are gone. WHY ALL THIS MATTERS: Production is the foundation of military responsiveness, so all of manufacturing is a defense technology to some extent. But defense is particularly suited to metal AM and metal AM leans toward the priorities of defense. Seeing this helps us understand a significant part of what metal AM is proving to be “for,” and where the next great impact of its further advance is likely to be found.   

Pentagon Tests Portable 3D-Printing Labs to Turn Battlefields Into Drone Factories Introduction The U.S. Department of Defense is experimenting with a radical shift in military logistics: replacing long, vulnerable supply chains with portable, on-demand manufacturing. In recent tests in Hawaii, the Pentagon demonstrated mobile 3D-printing labs that allow soldiers to design, print, and assemble drones within hours, directly in the field. What the Pentagon Is Testing The initiative focuses on deployable manufacturing units designed for austere environments. • Portable 3D-printing labs that can be transported and set up rapidly • Capability for troops to design drone components locally • End-to-end production, from digital design to assembled aircraft, in hours Why Drones Are the First Target Unmanned systems are ideal for battlefield manufacturing. • Drones are relatively small and modular • They are expendable and frequently lost in combat • Rapid iteration allows designs to be adapted to mission needs and enemy tactics Strategic Motivation The effort is driven by hard lessons from recent conflicts. • Traditional supply lines are fragile and easily targeted • Replacement parts and systems can take weeks or months to arrive • On-site production reduces dependence on centralized logistics hubs Operational Implications If scaled, this approach could reshape military operations. • Units gain autonomy to replace and modify equipment in real time • Logistics footprints shrink, improving survivability • Innovation cycles move from contractors to the tactical edge Why It Matters This test signals a shift toward distributed, software-driven warfare where manufacturing is as mobile as troops themselves. By turning battlefields into micro-factories, the Pentagon is betting that speed, adaptability, and resilience will outweigh mass production. If successful, on-demand manufacturing could redefine how future wars are fought, supplied, and sustained. I share daily insights with 35,000+ followers across defense, tech, and policy. If this topic resonates, I invite you to connect and continue the conversation. Keith King https://lnkd.in/gHPvUttw

The Pentagon announced three contracts to strengthen U.S. production of solid rocket motors (SRMs), a critical and vulnerable part of the defense supply chain. A four-year, $191.3 million contract was awarded to X-Bow Systems for advanced motor manufacturing, including the design, build, and demonstration of propellant production. X-Bow, founded in 2016, uses proprietary 3D-printing techniques and has worked with the Air Force Research Laboratory on additive manufacturing for SRMs. Additionally, two Defense Production Act (DPA) Title III awards totaling $33.5 million were announced to expand production capacity: Americarb received $12.6 million to develop insulating materials for rocket nozzles, and General Dynamics Ordnance and Tactical Systems received $20.9 million to expand nozzle production. The Pentagon emphasized that expanding SRM production is critical to national security, as solid rocket motors are used in tactical missiles, hypersonic weapons, and space-launch boosters, with demand increasing due to military operations in Ukraine and the Middle East. https://lnkd.in/eWmfKfgx #Defense #Pentagon #SolidRocketMotors #SRM #DefenseIndustry #Innovation #Manufacturing #NationalSecurity #Aerospace #AdditiveManufacturing #MilitaryTechnology