Additive Manufacturing
Articles tagged with Additive Manufacturing
"Reading the invisible": POSTECH-led team develops AI framework accounting for hidden defects in metal 3D printing
Toward artificial muscles that bend and twist on demand
Copper cold plates could slash data-center energy usage
Perovskite solar cells skip yellow phase, degrade slower thanks to key additives
Researchers at Rice University have developed a method to make perovskite-based photovoltaics more durable by adding two key ingredients, skipping the yellow phase and degrading slower. The films retain 98% of their initial efficiency even after 1,200 hours of exposure.
With a swipe of a magnet, microscopic “magno-bots” perform complex maneuvers
Engineers at MIT and their collaborators create a new type of soft magnetic hydrogel that can be made into complex, magnetically activated three-dimensional structures. The new gel enables the creation of microscopic, magnetically responsive robots and materials with micron-scale precision.
Computer-designed thermoelectric generator achieves more than eightfold improvement in efficiency
A breakthrough in computer-designed thermoelectric generators has achieved more than eight times better efficiency than conventional designs. The innovative approach uses topology optimization to precisely control heat flow and minimize electrical resistance.
Ultra-thin optical film sharpens 3D printing precision
A new ultra-thin optical film improves the quality of light used in LCD resin-based 3D printers, ensuring precise details and reducing printing errors. The film's design enhances collimation and uniformity, paving the way for affordable industrial or medical-grade products.
From lab to industry: 3D printing accelerates the future of lithium batteries
Recent progress in advanced energy manufacturing highlights 3D printing's potential to redefine next-generation lithium batteries. The technology enables precise control over three-dimensional structures, improving ion-transport pathways and mechanical robustness.
How an algorithm is curing 3D printing’s cracking problem
A team of researchers developed a machine learning framework to optimize laser settings for printing crack-susceptible superalloys. The algorithm reduced internal crack density by 99% and increased the metal's high-temperature strength, surpassing traditional cast components.
3D printing could change how cancer drugs reach tumors
Researchers at the University of Mississippi have developed a new method for delivering cancer-fighting drugs using 3D-printed nanocarriers, which can target specific tumor sites and minimize side effects. This innovative approach has shown promising results in killing cancer cells and reducing the impact of traditional chemotherapy.
Preview tool helps makers visualize 3D-printed objects
A new 3D printing preview tool, VisiPrint, uses AI to generate aesthetically accurate previews of fabricated objects, reducing the need for multiple reprints and waste. The system considers material properties, layer height, and nozzle path to create realistic simulations.
Machine learning designs cheaper and rust-proof steel for 3D printing
A new class of ultra-high strength and ductility steel has been created using machine learning, achieving a rare balance of extreme strength and ductility. The resulting metal resists corrosion and degrades slowly in salt-water tests.
Real-time X-rays reveal how a 'flash-freezing' alloy evades the stress of 3D printing
Researchers developed a bespoke aluminum alloy specifically tailored to survive and thrive in 3D printing. The new material produces components with significantly higher strength and lower internal stress than current industry standards.
Ultralight ‘organ-pipe’ structure absorbs noise with high structural strength
Researchers have created a carbon-fiber composite that swallows sound waves while retaining the strength of industrial load-bearing panels. The design achieves an average sound absorption coefficient of over 0.9 across a frequency range of 1,500 to 5,500 hertz.
How adding a microwave to a 3D printer makes flawless and heat-proof ceramics
Researchers used microwave-based 3D printing to create ceramic components with near-zero porosity and improved strength. The hybrid technique eliminates microscopic holes and traps gas bubbles, allowing for more bending force before breaking.
Printing living tissue at human-level cell density
Researchers create living tissue at near-physiological cell density using a new bioprinting strategy called embedded 3D printing in a cell-dense suspension (EPICS). The method enables the precise fabrication of perfusable channels and dense cellular environments, mimicking real organs.
Dynamic gel helps scientists grow organs more reliably in the lab
Scientists at UCSF created a new material that enables more predictable organoid growth, allowing for better study of disease and potential tissue replacement. The dynamic gel, invented by Zev Gartner, mimics the body's soft environment and enables precise 3D printing of stem cells.
3D printing soft robots
Researchers at Harvard's John A. Paulson School of Engineering and Applied Sciences have developed a new fabrication method for printing robotic devices with long filaments featuring precisely placed hollow channels. This allows the device to bend and deform in predetermined ways, enabling the creation of soft robots with predictable s...
Researchers find a way to 3D print one of industry’s hardest engineering materials
Hiroshima University researchers develop novel 3D printing method to produce cemented carbides with high hardness and durability, reducing material waste and cost. The new technique maintains the hardness of conventionally manufactured WC-Co cemented carbides without defects or decomposition.
Team develops smart synthetic material inspired by octopus skin
The team created a programmable smart skin out of hydrogel, enabling enhanced multifunctionality and adjustable properties. The material can encrypt or decrypt information, enable adaptive camouflage, power soft robotics, and more.
Low-temperature-activated deployment of smart 4D-printed vascular stents
Researchers developed smart 4D-printed vascular stents that expand naturally at body temperature, eliminating the need for external heating. The stents balance mechanical flexibility and radial strength, demonstrating long-term biomechanical compliance.
Your future home might be framed with printed plastic
MIT engineers have designed a 3D-printed floor truss system made from recycled plastic, which exceeds building standards set by the US Department of Housing and Urban Development. The printed flooring can hold over 4,000 pounds and weighs about 13 pounds per truss, making it a lighter alternative to traditional wood-based trusses.
Team develops smart synthetic material inspired by octopus skin
A team of researchers developed a programmable smart skin out of hydrogel that can be used to encrypt or decrypt information, enable adaptive camouflage and power soft robotics. The material's dynamic control over optical appearance, mechanical response and surface texture can be adjusted using external stimuli.
Dr. Barron Bichon promoted to vice president of SwRI’s Mechanical Engineering Division
Dr. Barron Bichon has been promoted to vice president of SwRI's Mechanical Engineering Division, overseeing a team of over 400 staff members. He will lead the division in advancing additive manufacturing and composite material bonding for defense and aerospace applications.
Underwater 3D printing could transform maritime construction
A Cornell University team is developing a method to 3D-print concrete underwater, which could revolutionize on-site maritime construction and repair of critical infrastructure. The technology aims to minimize ocean disruption while creating more efficient and effective construction methods.
New 3D printing method makes affordable, realistic replicas as structurally complex as a human hand
Researchers developed a new 3D printing method, CRAFT, that can create realistic models of body parts, including complex structures like bone and ligament. The method uses inexpensive commercial printers and widely available materials, enabling the creation of affordable and accurate replicas.
Compton highlights physics priorities of direct-ink writing in top journal
Direct-ink writing (DIW) technology faces unique physics puzzles, requiring a balance between liquid-like and solid-like behavior. The review aims to stimulate fundamental work on the central challenges of DIW, enabling more reliable and precise processes.
New method allows scientists to 3D-print structures within cells
Researchers have developed a new method to print custom microstructures directly into living cells, enabling the study of biological functions and instilling enhanced properties. The breakthrough uses light-sensitive materials and laser polymerization to create structures within cells.
Scientists demonstrate low-cost, high-quality lenses for super-resolution microscopy
Researchers develop a new fabrication approach to produce multi-element optical components for super-resolution imaging, enabling customized imaging systems. The technique uses consumer-grade 3D printers and low-cost materials, producing high-performance lenses at a cost of less than $1 each.
Wyss Institute-led collaboration awarded by ARPA-H PRINT program to engineer off-the-shelf, universal, transplant-ready graft for liver failure
A multidisciplinary team of world-leading experts is developing an off-the-shelf engineered product that could address liver failure in millions of patients. The ImPLANT project aims to create synthetic biology-based gene circuits in human induced pluripotent stem cells to drive cell differentiation into all required liver cell types.
Carnegie Mellon team awarded ARPA-H contract to develop 3D bioprinted liver for transplant
A Carnegie Mellon-led team has secured a $28.5 million award from ARPA-H to develop a functional, 3D bioprinted liver for patients with acute liver failure. The project aims to provide a temporary liver that supports regeneration of a patient's own liver, reducing the need for full organ transplants.
Seedcoat-inspired metal lets wings change shape on their own
Researchers at Nanjing University of Aeronautics and Astronautics created an active metal metamaterial that can bend and recover its shape, enabling aircraft wings to morph smoothly in flight. The material is lightweight, strong, and capable of adjusting its shape on demand.
Fighting skin diseases with 3D bioprinting
Researchers at TU Wien developed a 3D bioprinting technique to create living biological tissue for studying skin diseases. The method offers a controlled and highly reproducible manner to produce tailor-made structures for different purposes, such as psoriasis and inflammatory models.
Goodbye stereolithography: Scientists develop a faster and finer way to 3d print metal
Researchers create a new method for laser-based powder bed fusion that achieves unprecedented lattice walls and surfaces while reducing memory demand. The approach enables the high-fidelity fabrication of microscale shell lattices with improved strength and toughness.
How 3D printing creates stronger vehicle parts by solving aluminum’s high-temperature weakness
Researchers at Nagoya University created a new aluminum alloy series optimized for high strength and heat resistance through 3D printing. The study used low-cost elements to produce recycling-friendly materials that can operate at elevated temperatures, leading to lighter vehicles and reduced emissions.
3D-printed hydrogel “power patches” harvest low-grade heat as wearable thermocells
A research team at Nankai University has developed soft, stretchable 'power patches' that can be printed in various shapes and worn on the body to harvest low-grade heat. The patches generate a steady voltage when exposed to a temperature difference, making them suitable for wearable thermocells.
Multichannel 3D-printed bioactive scaffold combined with siRNA delivery for spinal cord injury recovery
Researchers developed an innovative treatment platform combining a multichannel 3D-printed bioactive scaffold with siRNA delivery for enhanced axon regeneration and improved motor function in spinal cord injury rats. The therapy addressed multiple pathological barriers, including insufficient intrinsic axonal regeneration, lack of dire...
Rodriguez and Phadatare selected for SME's 30 Under 30
Brittany Rodriguez and Akash Phadatare have been recognized by SME's 30 Under 30 program for their work in advancing manufacturing technologies. They are both part of the Manufacturing Demonstration Facility at ORNL, where they collaborate with industry partners to develop new methods for efficient and scalable manufacturing.
‘Artery on a chip': 3D printed blood vessels could unravel secrets of strokes
Researchers created a miniaturized replica of carotid arteries using 3D printing, mimicking the geometry and fluid dynamics of human blood vessels. The model revealed that platelet movement is crucial in blood clot formation, and high stress on blood vessels triggers significant platelet activity.
From artificial organs to advanced batteries: A breakthrough 3D-printable polymer
A new type of 3D-printable material made from polyethylene glycol has been developed by a University of Virginia research team. This breakthrough material is biologically friendly and can be stretched, making it suitable for use in larger structures or those requiring flexibility.
Novel “ink” for light-based 3D printing
Researchers developed a new methacrylate-based 'ink' that carries redox-active carbazole groups, enabling electrically conducting and color-changing materials. This allows for the creation of complex structures with reversible and pixel-level control.
Process monitoring of P-GMAW-based wire arc direct energy deposition of stainless steels via time-frequency domain analysis and Isolation Forest
Researchers developed an AI-based method to process high-frequency welding data, achieving a 28.3% improvement in anomaly detection performance. The approach uses time-frequency domain analysis and Isolation Forest to capture structural patterns underlying the repetitive nature of the welding process.
Like sculpting from within: New technique builds advanced materials out of basic plastics
Researchers at the University of Florida have developed a technique to create highly porous materials from everyday plastics by 'sculpting' from within. The new materials have potential applications in batteries, water filtration and high-density electronic storage.
Printing with fields: Reprogramming matter at the smallest scales
Researchers explore Field-assisted Additive Manufacturing for micro/nano device fabrication, enabling targeted motion, cell growth, and flexible electronics. The technology holds promise for industries such as biomedical engineering and microrobotics.
Muscle tissue from a 3D printer – produced in zero gravity
Researchers at ETH Zurich have successfully produced muscle tissue using a new biofabrication system called G-FLight in microgravity. The process enables rapid production of viable muscle constructs with similar cell viability and muscle fibers as those printed under gravity.
The next industrial revolution will be printed: global experts unpack the future of additive manufacturing
Global experts discuss the future of additive manufacturing in various applications, including bioprinting living tissues and creating smart consumer products. Researchers showcase advancements in machine learning, real-time sensing, and multi-material 3D printing.
3D-printed electrolytes keep zinc batteries stable for 8000 cycles
Researchers at South China University of Technology develop a method to solve unstable anode:electrolyte interfaces using digital light processing (DLP) 3D printing. The resulting batteries retain over 91% capacity after 8,000 cycles and achieve stable cycling over 2,000 hours.
Robots that flex like US: The rise of muscle-powered machines
Researchers are developing 'biohybrid robots' that flex and move using biological tissue, offering potential applications in medicine and industry. The field is advancing through advanced fabrication methods, such as 3D bioprinting and electrospinning, which enable precise control over muscle cells.
A new post-processing route to improve tensile strength and ductility in 3d-printed alloys
A new post-processing route improves tensile strength and ductility in 3D-printed alloys by combining deep cryogenic treatment and laser shock peening. This method transforms the microscopic structure of 3D-printed metals, relieving internal stresses and enhancing mechanical resilience.
Szeged researchers accelerate personalized medicine with AI-powered 3D cell analysis
Researchers at HUN-REN Szegedi Biológiai Kutatóközpont have developed an AI-powered platform for automated 3D cell culture analysis, enabling high-precision screening of cellular models. The technology removes the limitation of throughput in personalized medicine, allowing for fast and accurate analysis of clinical samples.
3D printed antenna arrays developed for flexible wireless systems
The WSU-led team created antennas that remain stable when bent or exposed to high humidity, temperature variations, and salt. They also developed a processor chip that can correct errant signals in real-time.
High-throughput inkless printing: Laser-generated dry aerosols enable green manufacturing of electronics
Researchers have developed Laser Ablation Dry Aerosol Printing (LADAP) that generates nanoparticles from solid targets using pulsed laser ablation, enabling the printing of metals and oxides without inks. The technique produces structures with fine-resolution microstructures and thick deposition within a high-throughput process.
Metamaterials can stifle vibrations with intentional complexity
A team of researchers at the University of Michigan and AFRL has developed a new method to create structures that passively impede vibrations, using complex geometry to elicit beneficial properties. The innovation builds on decades of theoretical research and utilizes advanced fabrication technologies like 3D printing.
Physics-based machine learning could unlock better 3D-printed materials
A new project aims to develop a computationally efficient model that accurately predicts how additive manufacturing process parameters influence the solidification microstructure of binary alloy solidification. This will enable optimization of additively manufactured parts with confidence in critical industries.
New open-source software allows for efficient 3D printing with multiple materials
OpenVCAD, a new open-source tool, enables efficient design of multi-material objects by mapping shapes and materials in 3D printing. The software package acts as a set of convenience tools for composing complex functions and assigning them to objects in a 3D printer.
Metal, melted, mastered
Researchers at Virginia Tech have developed an AI-powered system to detect flaws in wire-arc additive manufacturing, a faster approach to producing complex components. The technology enables real-time defect detection and correction, reducing waste and improving quality.
Printable aluminum alloy sets strength records, may enable lighter aircraft parts
Researchers at MIT have developed a 3D-printable aluminum alloy that is five times stronger than traditionally manufactured versions. This breakthrough could lead to lighter and more efficient aircraft parts, such as fan blades in jet engines, reducing energy consumption and costs.
ORNL composites research wins top CAMX awards
The Department of Energy's Oak Ridge National Laboratory received prestigious awards at the 2025 Composites and Advanced Materials Conference (CAMX) for its groundbreaking multiplexing extrusion system and collaborative research on composite rocket nozzles. These innovations aim to reduce costs and lead time in manufacturing, while inc...
Seoul National University of Science and Technology researchers develop 3D-printed carbon nanotube sensors for smart health monitoring
Seoul National University researchers create highly stretchable, electrically conductive carbon nanotube-based nanocomposites using vat photopolymerization type 3D printing. The new material is optimized for smart health monitoring applications, enabling real-time pressure distribution detection.