<p>For much of the history of printed circuit boards (PCBs) and electronics, development of new devices has been limited to highly skilled experts and organizations with the necessary resources. This is in large part an issue of cost, but has also come down to technological limitations, which have constrained how people are introduced to electronics design in an educational context. While theoretical lessons and rudimentary breadboards are useful for teaching the very basics of circuitry, students need a solution that gives them real hands-on experience in designing, testing, and validating electronic circuits. </p><p>Enter the <a href="https://www.voltera.io/products/v-one?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=v-one-hands-on-learning-pcb-design&amp;utm_content=v-one">V-One</a>, a PCB printer developed by <a href="https://www.voltera.io/about">Voltera</a>, a Canadian company that makes rapid prototyping platforms for printed electronics. This desktop tool is an affordable solution for educational institutions looking to give their students a high level of hands-on learning in PCB design. As we’ll explore in greater detail, the V-One has multiple functionalities, a shallow learning curve, and can be used at a range of levels for teaching simple circuitry or developing complex electronics. Ultimately, creating access to PCB design, even from a young age, is imperative to getting students excited about technological creation and empowering the next generation of innovators.</p><p><span><span><iframe src="https://www.youtube.com/embed/6TXIS79ZTt0?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" style="width:1920px;height:450px"><span> </span><span> </span><span> </span></iframe></span></span></p><h2>Getting to know the V-One</h2><p>The V-One offers educators an accessible platform for bringing PCB designs to life—both in terms of cost and learning curve. The sub-$4,500 benchtop printer integrates multiple functions including:</p><ul><li><p>Drilling holes into a substrate for through-hole components and double-sided PCBs</p></li><li><p>Printing traces from conductive ink based on digital designs </p></li><li><p>Depositing solder paste with higher precision than manual application</p></li><li><p>Reflow for soldering (as well as heating for curing conductive inks)</p></li></ul><p>These functions result in a versatile machine that can make anything from simple circuits, to double-sided PCBs, to flexible electronic prototypes (Voltera also offers a dedicated platform for flexible electronics, <a href="https://www.voltera.io/products/nova">NOVA</a>). Users can also manually place rivets or additional electronic components onto the printed board and use the V-One solder paste deposition and reflow tool to finalize the circuit.</p><p>Thanks to these capabilities, the V-One has become a popular tool for rapidly prototyping electronics and for teaching PCB design. Today, various educational institutions, from high-schools to Ivy League universities, have adopted the technology and have seen the benefits of teaching circuitry in a hands-on yet still highly efficient way. In short, the V-One allows students to translate their theoretical understanding of electronics to the real world and bring functional prototypes to life. </p><h2>Accessible interface for learning</h2><p>Part of what makes the V-One so well suited to the world of education is its user-friendly interface and simplified workflow. At the core of the system’s usability is Voltera’s free software platform, which guides users through the steps of preparing the V-One and initiating its various workflows (Print, Solder, Drill, and Heat). </p><p>Students working with the V-One can easily set-up the system for their circuit printing projects, answering prompts like what type of PCB is being printed (i.e. a blank board or a development board that has existing conductive traces) and what ink will be used. From there, they can upload their circuit design and initiate calibration, following a series of clear instructions accompanied by demonstration videos. It’s worth mentioning that having students use V-One’s four workflows will give them valuable first-hand knowledge of material properties, subtractive and additive manufacturing processes, and product development. If students have any questions along the way or any troubleshooting is required, Voltera’s software also integrates an in-app chat function.</p><h2>Case Study: 7-Segment Display Decimal Counter</h2><p>In South Korea, Voltera reseller ITIZ developed a <a href="https://www.voltera.io/use-cases/white-papers/printing-decimal-counter-circuit-silver-conductive-ink-fr1?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=v-one-hands-on-learning-pcb-design&amp;utm_content=lesson-plan">lesson plan</a> for teaching high school students about the fundamentals of electrical engineering and PCB design. The project has a fairly simple output—a decimal counter that counts from zero up to 99—but is designed to integrate many key PCB development concepts, covering different types of voltage regulation, variable resistors, wave pulse generation, and seven-segment displays.</p><p>In the educational program, students are tasked with creating three single-sided circuits: a voltage regulator that converts 9V input into 5V output, a wave pulse generator that turns that voltage into pulse signals, and a decimal counter board, which translates the pulses into an LED counter that goes up to 99. Students must go through the process of creating each of these three boards using the V-One, FR1 boards, conductive silver ink, and solder paste. When each individual board is printed, the students must also connect them to create the functional counter device, whose speed can be controlled by the pulse generator.</p><p><span><span><span><span><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742892384725-ezgif-28d4cf63ff862f.jpg" style="width:100%px" class="fr-fic fr-dib" /><span><em>7-Segment display decimal counter</em></span></span></span></span></span></p><p>“This project highlights the potential of additive PCB prototyping in electronics education,” writes Voltera. “By combining theory and practice, students can explore how digital counting systems function, understand the role of BCD-to-seven-segment conversion, and observe how timing signals interact with display components. Direct ink writing platforms like V-One empower the next generation of engineers to innovate beyond breadboards and rapidly iterate on electronics designs.”</p><h2>A V-One on Every Desk</h2><p>As we saw, the V-One gives students a hands-on way to learn the fundamentals of PCB development, but it can also be used for more complex projects as students advance in their education. For instance, students can make their own creative electronic devices using the V-One and 3D printers, such as bluetooth speakers, lighting fixtures, or interactive toys. As their skills further develop, it is possible to design and make even more complex PCBs, like a custom breakout board for a <a href="https://www.voltera.io/use-cases/white-papers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control">remote-controlled robotic hand</a> or <a href="https://www.voltera.io/use-cases/customer-stories/princeton-university">CubeSats to be launched into space to gather data</a>. </p><p><span><span><span><span><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742892484412-ezgif-209fdbef39ef8e.jpg" style="width:100%px" class="fr-fic fr-dib" /><span><em>A project completed using V-One by students in South Korea</em></span></span></span></span></span></p><p><span><span><br /></span></span>The key difference between the V-One and more traditional tools for learning circuitry design, like breadboards, is that students can actually test and refine their PCBs. Moreover, this can be done directly in the classroom and often in less than an hour. This enables students to design, print, test, and reiterate PCBs directly without having to depend on external prototyping services. Ultimately, this gives students the opportunity to conduct multiple experiments and projects within a single semester, expanding their skills and knowledge at a more significant rate.</p><p><span><span><span><span><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742892605240-ezgif-289b8803016144.jpg" style="width:100%px" class="fr-fic fr-dib" /><span><em>A South Korea classroom with a V-One for each student</em></span></span></span><em><br /></em></span></span></p><p>As Shannen Prindle, a student from <a href="https://www.voltera.io/use-cases/customer-stories/princeton-university?utm_campaign=Wevolver&amp;utm_source=wevolver&amp;utm_medium=v-one-hands-on-learning-pcb-design&amp;utm_content=princeton-university">Princeton University</a> who worked on CubeSats using the V-One, said: “If we didn't have something like the Voltera V-One (...) I don't think I would fully understand what goes into a circuit. Being able to see where the electronics go helped me understand what components go where.”</p><h2>Conclusion</h2><p><a href="https://news.harvard.edu/gazette/story/2019/09/study-shows-that-students-learn-more-when-taking-part-in-classrooms-that-employ-active-learning-strategies/">Research</a> has shown that hands-on, active learning has clear benefits for understanding concepts and knowledge retention. This is particularly true in fields like electronics engineering that rely on a combination of digital and physical tools to create functional devices. The V-One can thus improve how students learn about electronics and PCBs, offering an accessible platform for bringing circuit designs to physical life. In the end, getting V-One modules into the hands of educators and students will allow for greater access to PCB development and equip the next generation with the skills needed to develop innovative new solutions in the field of electronics.</p>

V-One, a PCB printer developed by Voltera, a Canadian company that makes rapid prototyping platforms for printed electronics.

Learn by Printing: How the V-One Empowers Hands-On Learning in PCB Design

<p>Sometimes big things start small, and that’s certainly true of filament manufacturer Fiberthree. This Darmstadt-based company has developed a process that recycles carbon-fiber-reinforced plastic and significantly minimizes its carbon footprint. At the same time, the recycled material involves no additional costs and offers almost the same mechanical properties. While recycled material still accounts for less than 10 percent its total sales, Klaus Philipp, co-founder and managing director of Fiberthree, wants to position his company more strongly in this field.</p><p><span><span><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742801418406-Abfall_content.webp.1280.webp" style="width:100%px" class="fr-fic fr-dib" /><span>New filaments are created from support structures, rejects or misprints. Image: Fiberthree.</span></span></span></p><p>An important driver of this development was the mechanical engineering company Andritz Kaiser, which has been sourcing its filament from Fiberthree for many years. “We generate a lot of waste, particularly when developing new components – be it in the form of support structures, rejects, or misprints,” says Paolo Matassoni, head of development at Andritz Kaiser. “Material is a precious raw material and it's far too good to simply throw away.” Matassoni and his team collect the waste from the 120 kilograms of carbon-fiber-reinforced plastic that is printed at Andritz Kaiser each year and send it back to Darmstadt, along with their empty filament spools. As Andritz Kaiser also has the components for its series machines 3D-printed at Fiberthree, further residual materials from Fiberthree’s PA-CF Pro plastic are collected here, as well.</p><table><tbody><tr><td><h3>Stay Informed on the Latest FormNext 2025 Updates! Sign up to the FormNext newsletter to get notified as soon as tickets are available.</h3><p><a href="https://info.mesago.de/-lp/5HKPB14784/p4jkP173" target="_blank" rel="nofollow" class="button-main-action">Sign up here</a></p></td></tr></tbody></table><h2>Recycling process presents challenges</h2><p>Klaus Philipp is particularly motivated by the desire to ensure that the remnants of PA-CF Pro do not end up as waste. “In this day and age, we can no longer afford to simply throw away a high-performance material. We have to realize that plastics have value.” This recycling approach is also important because “we have young employees who are very committed to the issue of sustainability,” as Philipp explains.</p><p><span><span><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742801452704-Fiberthree-02.webp.768.webp" style="width:100%px" class="fr-fic fr-dib" /><span>According to Fiberthree, the recycled material achieves around 90 percent of the performance of the original filament. Images: Fiberthree </span></span></span></p><p>Fiberthree, which employs four people and sells around three tons of plastic per year, now collects 250 kilograms of PA-CF Pro per year for recycling. In the first step, the material is shredded by a partner in the region. What sounds trivial is a challenge with a material like carbon-fiber-reinforced plastic: “It puts a lot of strain on the machine and can wear it out,” Philipp points out. Next, the shredded material is processed into granulate and then into filament. The intermediate step to granulate takes place “for safety reasons,” Philipp continues. “Otherwise, any contamination could damage the filament extruder.” This makes clean separation even more important.</p><h2>Technical properties almost like the original</h2><p>“Technically, the recycled material is almost as good as before; we achieve around 90 percent of the performance of the original filament,” Philipp reports. For Matassoni, the material’s slightly diminished strength is not a problem: “We don't use the recycled material for high-strength applications, but for support structures, for example, or for components such as oil pipes that are not exposed to high tensile or compressive forces.” Further tests are currently underway at Andritz Kaiser to determine the exact technical properties of the material. The results should be available by the end of 2024.</p><p><span><span><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742801504348-druckservice.webp.1280.webp" style="width:100%px" class="fr-fic fr-dib" /><span>Filament production and tests on the company's own printers are carried out in-house in Darmstadt. Images: Fiberthree</span></span></span></p><h2 id="isPasted">Up to 90 percent less CO2</h2><p>PA-CF Pro is a polyamide 6 with a carbon fiber content of 15 percent. Philipp has calculated that producing one kilogram of this material generates 10 to 12 kg of CO2 emissions. This is based on the CO2 footprints of polyamide (around 5 kg of CO2 / kg of material) and carbon fiber (30 kg of CO2 / kg of material) and that of compounding and filament production.</p><p>Philipp anticipates that Fiberthree’s recycling process will lead to significant reductions in CO2. For large tonnages, the rates achieved can reach 90 percent, and 60–80 percent can still be achieved with smaller quantities. One variable here is the use of electricity – that is, whether you include green electricity or the electricity mix in Germany. On average, Philipp has calculated three kilograms of CO2 emissions for each kilogram of recycled material.</p><p>Recycling has not yet saved any money, but there are no additional costs, either. The price of the recycled material is the same as that of new filament. “And that's already a strong argument,” asserts a happy Paolo Matassoni. “You reduce CO2 at practically zero cost.” This means that recycling will also be of interest to companies and corporations that are committed to sustainability and are pursuing set goals in this area. “The great thing about this application is that it’s very honest. Sustainability is not glossed over here; it is tangible,” Matassoni points out.</p><table><tbody><tr><td><h3>Stay Informed on the Latest FormNext 2025 Updates! Sign up to the FormNext newsletter to get notified as soon as tickets are available.</h3><p><a href="https://info.mesago.de/-lp/5HKPB14784/p4jkP173" target="_blank" rel="nofollow" class="button-main-action">Sign up here</a></p></td></tr></tbody></table>

Sometimes big things start small, and that’s certainly true of filament manufacturer Fiberthree. This Darmstadt-based company has developed a process that recycles carbon-fiber-reinforced plastic and significantly minimizes its carbon footprint.

Reducing CO2 at zero cost

<p>The 4th International 4D Materials Design and Additive Manufacturing Conference 2025 (4DMDA 2025) is organized by A*STAR's Research Institutes, Universities, and the 4D Printing Society. </p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742556201010-ASTAR-4DP.png" style="width:100%px" class="fr-fic fr-dib" /></p><p>The event showcases the latest developments and technologies in smart materials, metamaterials, intelligent designs, modelling, additive manufacturing, and 3D/4D printing. It addresses current concerns in the further development of 3D/4D printed devices. It provides a forum for internationally recognized experts and young scientists working in the fields of smart materials, metamaterials, advanced design, modelling and simulation, and 3D/4D printing technologies to present their work.</p><p>This conference is hosted in person at the Advanced Remanufacturing and Technology Centre (ARTC), Singapore, and is scheduled to take place on July 8-10, 2025.</p><p><a href="https://4dprintings.com/events/4dmda2025/"><strong>REGISTER HERE</strong></a></p>

Organized by A*STARs Research Institutes and Universities, and the 4D Printing Society

EVENT: 4D Materials Design and Additive Manufacturing Conference 2025

<p>3D electronics printing is a rapidly growing area of electronics production that combines nanotechnology, elements of additive manufacturing, and nanomaterials. These nanomaterials are inks or viscous pastes that contain carbon, metallic, semiconductor, or ceramic nanoparticles that provide desirable electrical properties.</p><p>While this area of electronics printing can be considered different to 3D printing proper—printed circuits can have multiple layers, but typically have a limited Z-axis—it borrows many features from other types of additive manufacturing. For example, printheads are operated via ultra-precise computer numerical control (CNC) on a gantry system. On the other hand, nanomaterials for electronics are often printed using techniques that are less common in other areas of industrial or consumer 3D printing, such as dispensing, direct ink writing, aerosol jet, or drop-on-demand inkjet.[1]</p><p>One of the most important elements of 3D electronic printing, besides the use of highly innovative nanomaterials, is the use of multi-material circuits. 3D electronics systems can provide the ability to print multiple materials in a single circuit via multi-nozzle setup or the rapid changeover of material cartridges within a single-nozzle setup. The combination of conductive nanoparticle inks and pastes (and other materials) can lead to next-generation electronic possibilities.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742471972239-hfs.png" style="width:100%px" class="fr-fic fr-dib" /></p><h2>The Role of Nanomaterials in 3D Electronics Printing</h2><p>Nanomaterials are crucial to the development of 3D electronics printing applications because they allow electrically functional materials like silver to be manipulated and arranged in an ultra-precise manner that would not be possible in other material forms.</p><p>In short, nanomaterials consist of two main components:</p><ol><li><p>An easily printable <strong>matrix</strong> material. In extrusion printing, this might be an ordinary thermoplastic polymer; in dispensing it may be a glycol or glycol ether, for example.</p></li><li><p>A significant concentration of <strong>nanoparticles</strong>. These are the critical functional ingredients of the nanomaterial and may be of a material such as silver, copper, or carbon.</p></li></ol><p>Nanomaterials such as silver inks and pastes are highly beneficial in 3D electronics printing technology due to their high conductivity, their ability to be printed through ultra-fine dispensing, aerosol, and other printing techniques, and their adhesion to various substrates. Silver nanoparticles enable fine, precise circuit patterns for applications like RFID antennas, touchscreens, and flexible sensors. Additionally, the concentration of nanoparticles can be varied to produce <a href="https://xtpl.com/nanomaterials-in-3d-electronics-printing-xtpl/">nanomaterials</a> with different electrical properties and viscosities.[2]</p><p>Compared to traditional etching methods, nano inks minimize material waste and enable scalable, cost-effective, miniaturized manufacturing. Special nano-engineered formulations can also enhance the oxidation resistance and mechanical flexibility of the printed components, which can be useful in applications like wearables, medical devices, and Internet of Things (IoT) technologies.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742471991304-microled.png" style="width:100%px" class="fr-fic fr-dib" /></p><h2>Multi-Material Circuits: Expanding the Horizons</h2><p>Multi-material circuits are advantageous because they enhance device functionality by integrating different material properties in a single fabrication process. For instance, combining conductive and insulating materials enables complex interconnects without additional processing steps. This is particularly beneficial in advanced electronics applications like flexible hybrid electronics, microfluidics, and semiconductor packaging.</p><p><a href="https://xtpl.com/ultra-precise-dispensing/" target="_blank" rel="noopener noreferrer">XTPL's Ultra-Precise Deposition (UPD) technology</a> enables multi-material circuit printing by allowing precise deposition of conductive silver inks and pastes at the microscale and offering a rapid material changeover via its cartridge system. Other printable materials include dielectrics, photoresists, and quantum dots, while XTPL can also develop novel nanomaterials alongside customers to discover new applications. Furthermore, multiple UPD printheads can be operated simultaneously for multi-material dispensing.</p><p>UPD’s capability to print on various substrates, including flexible, transparent, and rough-textured ones, and even on vertical substrates using its high-viscosity Ag Nanopaste CL85, supports the development of 3D devices like next-generation wearable electronics, high-density interconnects, and custom microsensors.</p><h2>The Future of 3D Electronics Printing</h2><p>3D electronics printing is on course for a bright future as nanomaterials, multi-material circuits, and ultra-precise deposition techniques continue to evolve. The integration of conductive inks, dielectrics, and novel substrates will enable the development of flexible, miniaturized, and highly efficient electronic devices.</p><p>With the emergence of sub-micron dispensing technologies and an expanding nanomaterial range, applications in areas like wearables, medical devices, and IoT will accelerate and broaden. Additionally, innovations in deposition methods, such as XTPL’s UPD, will continue to enhance manufacturing precision through its dispensing of ultra-fine traces. In the future, fully functional 3D printed electronic systems—combining circuitry, sensors, and even power sources—may become standard, while the use of cutting-edge printing technologies on production lines will enable such devices to become mainstream.</p><h2>Resources</h2><p>[1] Persad J, Rocke S. A survey of 3D printing technologies as applied to printed electronics. Ieee Access. 2022 Mar 8;10:27289-319.</p><p>[2] Apmann K, Fulmer R, Soto A, Vafaei S. Thermal conductivity and viscosity: Review and optimization of effects of nanoparticles. Materials. 2021 Mar 8;14(5):1291.</p>

New electronics printing technologies enable the production of miniature, high-performance 3D electronic devices, with nanomaterials being key to the process

From Nanomaterials to Multi-Material Circuits: The Future of 3D Electronics Printing

<p>It’s difficult to build devices that replicate the fluid, precise motion of humans, but that might change if we could pull a few (literal) strings.</p><p>At least, that’s the idea behind “cable-driven” mechanisms in which running a string through an object generates streamlined movement across an object’s different parts. Take a robotic finger, for example: You could embed a cable through the palm to the fingertip of this object and then pull it to create a curling motion.</p><p>While cable-driven mechanisms can create real-time motion to make an object bend, twist, or fold, they can be complicated and time-consuming to assemble by hand. To automate the process, researchers from MIT’s Computer Science and Artificial Intelligence Laboratory (CSAIL) have developed an all-in-one 3D printing approach called “Xstrings.” Part design tool, part fabrication method, Xstrings can embed all the pieces together and produce a cable-driven device, saving time when assembling bionic robots, creating art installations, or working on dynamic fashion designs.</p><p><em>3D printing approach strings together cable-driven mechanisms for you<br />Video: MIT CSAIL</em></p><p>In a <a href="https://groups.csail.mit.edu/hcie/files/research-projects/xstrings/xstrings.pdf" target="_blank">paper</a> to be presented at the 2025 Conference on Human Factors in Computing Systems (CHI2025), the researchers used Xstrings to print a range of colorful and unique objects that included a red walking lizard robot, a purple wall sculpture that can open and close like a peacock’s tail, a white tentacle that curls around items, and a white claw that can ball up into a fist to grab objects.</p><p>To fabricate these eye-catching mechanisms, Xstrings allows users to fully customize their designs in a software program, sending them to a multi-material 3D printer to bring that creation to life. You can automatically print all the device’s parts in their desired locations in one step, including the cables running through it and the joints that enable its intended motion.</p><p>MIT CSAIL postdoc and lead author Jiaji Li says that Xstrings can save engineers time and energy, reducing 40 percent of total production time compared to doing things manually. “Our innovative method can help anyone design and fabricate cable-driven products with a desktop bi-material 3D printer,” says Li.</p><h2><strong>A new twist on cable-driven fabrication</strong></h2><p>To use the Xstrings program, users first input a design with specific dimensions, like a rectangular cube divided into smaller pieces with a hole in the middle of each one. You can then choose which way its parts move by selecting different “primitives:” bending, coiling (like a spring), twisting (like a screw), or compressing — and the angle of these motions.</p><p>For even more elaborate creations, users can incorporate multiple primitives to create intriguing combinations of motions. If you wanted to make a toy snake, you could include several twists to create a “series” combo, in which a single cord drives a sequence of motions. To create the robot claw, the team embedded multiple cables into a “parallel” combination, where several strings are embedded, to enable each finger to close up into a fist.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742432637463-mit-Xstrings-diagram.png" style="width:100%px" class="fr-fic fr-dib" />Xstrings facilitates how cables are integrated into the object it’s producing. Users can choose exactly how the strings are secured, including its endpoint, the holes within the structure that the cord passes through, and where you’d pull to operate the device. <br />Image courtesy of the researchers.</p><p>Beyond fine-tuning the way cable-driven mechanisms move, Xstrings also facilitates how cables are integrated into the object. Users can choose exactly how the strings are secured, in terms of where the “anchor” (endpoint), “threaded areas” (or holes within the structure that the cord passes through), and “exposed point” (where you’d pull to operate the device) are located. With a robot finger, for instance, you could choose the anchor to be located at the fingertip, with a cable running through the finger and a pull tag exposed at the other end.</p><p>Xstrings also supports diverse joint designs by automatically placing components that are elastic, compliant, or mechanical. This allows the cable to turn as needed as it completes the device’s intended motion.</p><h2><strong>Driving unique designs across robotics, art, and beyond</strong></h2><p>Once users have simulated their digital blueprint for a cable-driven item, they can bring it to life via fabrication. Xstrings can send your design to a fused deposition modeling 3D printer, where plastic is melted down into a nozzle before the filaments are poured out to build structures up layer by layer.</p><p>Xstrings uses this technique to lay out cables horizontally and build around them. To ensure their method would successfully print cable-driven mechanisms, the researchers carefully tested their materials and printing conditions.</p><p>For example, the researchers found that their strings only broke after being pulled up and down by a mechanical device more than 60,000 times. In another test, the team discovered that printing at 260 degrees Celsius with a speed of 10-20 millimeters per second was ideal for producing their many creative items.</p><p>“The Xstrings software can bring a variety of ideas to life,” says Li. “It enables you to produce a bionic robot device like a human hand, mimicking our own gripping capabilities. You can also create interactive art pieces, like a cable-driven sculpture with unique geometries, and clothes with adjustable flaps. One day, this technology could enable the rapid, one-step creation of cable-driven robots in outer space, even within highly confined environments such as space stations or extraterrestrial bases.”</p><p>The team’s approach offers plenty of flexibility and a noticeable speed boost to fabricating cable-driven objects. It creates objects that are rigid on the outside, but soft and flexible on the inside; in the future, they may look to develop objects that are soft externally but rigid internally, much like humans’ skin and bones. They’re also considering using more resilient cables, and, instead of just printing strings horizontally, embedding ones that are angled or even vertical.</p><p>Li wrote the paper with Zhejiang University master’s student Shuyue Feng; Tsinghua University master’s student Yujia Liu; Zhejiang University assistant professor and former MIT Media Lab visiting researcher Guanyun Wang; and three CSAIL members: Maxine Perroni-Scharf, an MIT PhD student in electrical engineering and computer science; Emily Guan, a visiting researcher; and senior author Stefanie Mueller, the TIBCO Career Development Associate Professor in the MIT departments of Electrical Engineering and Computer Science and Mechanical Engineering, and leader of the HCI Engineering Group.</p>

The “Xstrings” method can produce a range of colorful and unique objects, like a white tentacle that curls around items and a purple wall sculpture that can open and close. Photo: Mike Grimmett/MIT CSAIL

“Xstrings” method enables users to produce cable-driven objects, automatically assembling bionic robots, sculptures, and dynamic fashion designs.

3D printing approach strings together dynamic objects for you

<p>3D printing is gaining increased traction in the defense sector as its unique advantages can be leveraged to provide fast, cost-effective manufacturing solutions.</p><p>With a wide range of applications, the ability to produce spare parts on demand, create custom tools and jigs, help streamline the maintenance workflow, and reduce logistical challenges associated with traditional supply chain alternatives.</p><p><a href="https://ultimaker.com/">UltiMaker’s ecosystem</a>, including <a href="https://ultimaker.com/software/ultimaker-digital-factory/">Digital Factory</a> for remote print management, enables defense organizations to integrate 3D printing into their workflows effectively. In this article, we aim to outline the key benefits and some of the potential applications of 3D printing in defense.</p><h2>Benefits of 3D printing in defense</h2><p>There are 5 main benefits that offer key advantages for defense applications:</p><h3>On-demand spare parts production</h3><p>Traditional supply chains require stockpiling spare parts, which takes up space and can lead to long lead times if a part is unavailable. With 3D printing, essential components can be produced on-site, reducing downtime and ensuring mission-critical equipment remains operational.</p><p>A professional desktop 3D printer is a compact all-in-one additive manufacturing station that can be deployed in forward areas and is ready out of the box or with minimal setup.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742369309404-the-royal-netherlands-navy-fleet-of-printers+%281%29.webp" /></p><h3>Reduced logistical challenges</h3><p>Transporting spare parts, tools, and equipment is costly and resource-intensive. 3D printing’s inherent advantage is that it minimizes this burden by allowing parts to be manufactured as needed, reducing the need for large storage facilities and complex resupply operations.</p><h3>Wide range of materials</h3><p>Modern 3D printers support a wide variety of materials, including high-performance composites and metal alternatives, making it possible to produce durable and functional parts suitable for demanding defense operations.</p><p>For example, <a href="https://ultimaker.com/learn/on-demand-spare-parts-the-royal-netherlands-navys-3d-printing-solution/">the Royal Netherlands Navy</a> and UltiMaker collaborated on an application to verify the material strength of a 3D printed link to lift a 12-ton tank. Not only did the part successfully withstand the test but it did so while being produced faster (it takes a lot less time to 3D print a solid 2 kg link than to manufacture it via traditional methods) but it was also lighter than traditional metal link.</p><p></p><h3>Faster maintenance and repairs</h3><p>Custom tools, components, and maintenance jigs and fixtures can be printed on-site, reducing the time required to keep equipment in service. For example, the Royal Netherlands Air Force uses UltiMaker 3D printers to create maintenance tools for aircraft, speeding up servicing operations.</p><p>For example, during the transportation of jet engines, certain openings need to be covered with a special cap. While normally expensive to purchase and with often high delivery times, with 3D printing they can be manufactured in as little as 2 hours per part.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742369345602-Air-Force-blog-image-1.webp" /></p><h3>Digital inventory and remote print management</h3><p>Instead of relying on physical stockpiles, military units can maintain a digital inventory of spare parts accessible from any location via UltiMaker’s DigitalFactory. Prints can also be managed remotely, ensuring that necessary components are produced efficiently and delivered where they are needed.</p><p>The ability to manufacture components locally is especially beneficial in instances where traditional supply chains face difficulties due to unexpected rise in the demand for parts, bad weather, or adversarial denial.</p><p>For example, naval ships can keep a small fleet of 3D printers onboard and only stock filament spools with various materials vastly reducing the weight and space that would otherwise be occupied by spare parts in storage. The Royal Netherlands Navy for example employs UltiMaker 3D printers on board its ships to print a variety of replacement parts like water filters, valve handles, etc. Using UltiMaker Digital Factory they could securely source the 3D files, monitor the printers, and ensure that their data remained protected throughout the process without compromising on accessibility.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742369378494-1742369378494.png" /></p><h2>Expanding applications beyond logistics and maintenance</h2><p>While 3D printing has proven its value in defense logistics, maintenance, and supply resilience, its versatility can extend even further.</p><p>Beyond producing spare parts or mission-specific tools, additive manufacturing can make an impact in medical and humanitarian applications supported by the defense industry. Custom prosthetics, field medical devices, and protective gear can be 3D printed on demand ensuring that deployed personnel receive essential support in challenging environments as part of relief efforts.</p><p>By integrating 3D printing into defense workflows organizations can improve readiness, reduce logistical strain, and ensure adaptability in an ever-changing landscape.</p><p>If you want to know how you can leverage UltiMaker’s 3D printing ecosystem for your defense applications, don’t hesitate to <a href="https://ultimaker.com/quote-request/">get in touch with us.</a></p>

UltiMaker’s ecosystem, including Digital Factory for remote print management, enables defense organizations to integrate 3D printing into their workflows effectively. In this article, we aim to outline the key benefits and some of the potential applications of 3D printing in defense.

3D Printing in Defense: Applications and Benefits

<p>AI, as you may have noticed, is everywhere. Whether it is a discussion about political elections, the implications for recruitment, education or for manufacturing, AI is seemingly always a key part of the conversation. Applications of AI models are nascent across all use cases, including within AM. In this area, the National Institute of Standards and Technology (NIST) is currently running the Advanced Informatics and Artificial Intelligence for Additive Manufacturing (AI2AM) project to develop the methods, models, standards, and best practices to leverage AI and related technologies to move AM towards “born qualified” and “first part correct” outcomes. </p><table><tbody><tr><td><h3 id="isPasted">Stay Informed on the Latest FormNext 2025 Updates! Sign up to the FormNext newsletter to get notified as soon as tickets are available.</h3><p><a href="https://info.mesago.de/-lp/5HKPB14784/p4jkP173" target="_blank" id="isPasted" class="button-main-action">Sign up here</a></p></td></tr></tbody></table><p>Despite the fledgling nature of much of the technology, in the world of AM, different types of AI do, will or could find use across the process chain.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQyMjg2ODAxMzY5LUNoZXNzLndlYnAuMTI4MC53ZWJwIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii" />In addition to design, AI offers support in further process steps in Additive Manufacturing. Image: James Woodock</p><h2><strong>Ideation and design</strong></h2><p>AI can play a significant role in the DfAM space, with generative AI able to create complex designs that make full use of the benefits of AM. As well as being embedded in major CAD software like Autodesk Fusion 360 and Siemens NX, standalone products like Meshy AI allows users to create 3D models — exportable as .stl files — from either text prompts or photographs. Deploying deep learning and generative design in this way drastically reduces the design time while allowing more solutions to be trialed in a reduced timeframe.</p><p>Once part files have been generated, several AI processes including machine learning, predictive analytics and physics-informed AI software can then be used to analyze and fix files prior to printing. By analyzing the parts and mining known datasets about how different AM systems build, solutions like 1000 Kelvin’s AMAIZE, can predict issues with individual builds based on the part geometry, machine parameters and materials choice, reducing the number of failed builds.</p><p>Here is a concrete example: The Citrine Platform was used in collaboration with the Alliance for the Development of Additive Processing Technologies (ADAPT) Consortium to optimize the design and production of hinges for Mine-Resistant Ambush Protected (MRAP) light tactical vehicles. AI-driven optimization led to a 50% increase in strength, 38% reduction in weight, and consolidated the original six parts down to one.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQyMjg2ODM3ODc4LVRyYWRlc2hvdy53ZWJwLjEyODAud2VicCIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" class="fr-fic fr-dii" />Exhibition stand designed with AI. Image: James Woodcock</p><h2><strong>Defining the build</strong></h2><p>Machine learning (ML) models can analyze huge material datasets and combine that information with data from previous builds to predict how a given material will behave during the printing process. This allows engineers to make informed decisions about which materials to use for an application based on real-world data.</p><p>Predictive analytics AI ensures that schedules are optimized for maximum efficiency, helping manufacturers reduce downtime by planning and scheduling optimal times to run certain print jobs, based on machine availability, material stocks, and job priorities.</p><h2><strong>AI as QA<br /></strong></h2><p>AM processes, especially in metals, require the complex choreography of chemistry and physics. Things can and do go wrong. AI-based computer vision systems use deep learning to track each layer of a print as it is being produced, flagging defects such as layer shifts, warping, or other inconsistencies in real-time. Where fixes can be implemented, feedback loops can action corrections, at the very least part builds can be stopped at the point of failure instead of letting the process run.</p><p>Once the parts are built, inspection is still required — a time-consuming process open to human error. AI-driven automated inspection systems solve this by using computer vision and deep learning to analyze parts post-production. Companies like EOS have integrated computer vision into their platforms to provide real-time process monitoring (EOSCONNECT), ensuring that defects are identified early in the process. Oqton’s Build Quality combines build simulation, monitoring, and part inspection to ensure parts are built to specification without human interference.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQyMjg2ODY1MTQ0LVJvYm90LndlYnAuMTI4MC53ZWJwIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii" />AI also helps to monitor and maintain machines. Image: James Woodcock</p><p>Perennial bugbear, post-processing, can also be automated with AI-driven robotic systems, further optimizing the production workflow, and ensuring consistent results by handling support removal and surface finishing.</p><h2><strong>Future failure alert</strong></h2><p>Predictive maintenance — i.e., fixing a system before it breaks — is one of the most significant areas where AI adds value to users of AM systems. By using machine learning and IoT/IIoT-enabled sensors, AI can monitor the health of AM machines and predict when maintenance is required before a breakdown occurs. This proactive approach minimizes unplanned downtime, reduces repair costs, and extends machine lifespan. By integrating predictive maintenance solutions, manufacturers can achieve 20% efficiency gains and increase machine utilization, significantly enhancing profitability. </p><h3><strong>Explanation of terms</strong></h3><p><strong>Machine Learning          <br /></strong></p><p>A subset of AI focused on building systems that learn from data to make predictions or decisions without being explicitly programmed for each task.</p><p><strong>Deep Learning</strong></p><p>A subset of machine learning that uses neural networks to model complex patterns in data. Deep learning is particularly effective for tasks like image and speech recognition.</p><p><strong>Generative Models       </strong></p><p>AI models designed to generate new data samples that resemble the training data. These models can create new text, images, music, or other content.</p><p><strong>Neural Networks<br /></strong></p><p>A set of algorithms modelled loosely after the human brain, designed to recognize patterns.</p><table><tbody><tr><td><h3>Stay Informed on the Latest FormNext 2025 Updates! Sign up to the FormNext newsletter to get notified as soon as tickets are available.</h3><p><a href="https://info.mesago.de/-lp/5HKPB14784/p4jkP173" target="_blank" rel="nofollow" class="button-main-action">Sign up here</a></p></td></tr></tbody></table>

An overview of the current state of artificial intelligence in Additive Manufacturing with a special focus on the areas of idea generation and design, the construction process, quality assurance and future error prevention.

The next hype cycle?

<html><head></head><body><p id="isPasted">We move thanks to coordination among many skeletal muscle fibers, all twitching and pulling in sync. While some muscles align in one direction, others form intricate patterns, helping parts of the body move in multiple ways.</p><p>In recent years, scientists and engineers have looked to muscles as potential actuators for “biohybrid” robots — machines powered by soft, artificially grown muscle fibers. Such bio-bots could squirm and wiggle through spaces where traditional machines cannot. For the most part, however, researchers have only been able to fabricate artificial muscle that pulls in one direction, limiting any robot’s range of motion.</p><p>Now MIT engineers have developed a <a href="https://pubs.rsc.org/en/content/articlelanding/2025/bm/d4bm01017e" target="_blank">method to grow artificial muscle tissue</a> that twitches and flexes in multiple coordinated directions. As a demonstration, they grew an artificial, muscle-powered structure that pulls both concentrically and radially, much like how the iris in the human eye acts to dilate and constrict the pupil.</p><p>The researchers fabricated the artificial iris using a new “stamping” approach they developed. First, they 3D-printed a small, handheld stamp patterned with microscopic grooves, each as small as a single cell. Then they pressed the stamp into a soft hydrogel and seeded the resulting grooves with real muscle cells. The cells grew along these grooves within the hydrogel, forming fibers. When the researchers stimulated the fibers, the muscle contracted in multiple directions, following the fibers’ orientation.</p><p>“With the iris design, we believe we have demonstrated the first skeletal muscle-powered robot that generates force in more than one direction. That was uniquely enabled by this stamp approach,” says Ritu Raman, the Eugene Bell Career Development Professor of Tissue Engineering in MIT’s Department of Mechanical Engineering.</p><p>The team says the stamp can be printed using tabletop 3D printers and fitted with different patterns of microscopic grooves. The stamp can be used to grow complex patterns of muscle — and potentially other types of biological tissues, such as neurons and heart cells — that look and act like their natural counterparts.</p><p>“We want to make tissues that replicate the architectural complexity of real tissues,” Raman says. “To do that, you really need this kind of precision in your fabrication.”</p><p>She and her colleagues <a href="https://pubs.rsc.org/en/content/articlelanding/2025/bm/d4bm01017e" target="_blank">published their open-access results Friday in the journal <em>Biomaterials Science</em></a>. Her MIT co-authors include first author Tamara Rossy, Laura Schwendeman, Sonika Kohli, Maheera Bawa, and Pavankumar Umashankar, along with Roi Habba, Oren Tchaicheeyan, and Ayelet Lesman of Tel Aviv University in Israel.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742260285838-MIT-MuscleStamp-02-press.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The researchers developed a new “stamping” approach. First, they 3D-printed a small, handheld stamp (top images) patterned with microscopic grooves, each as small as a single cell. Then they pressed the stamp into a soft hydrogel and seeded the resulting grooves with real muscle cells. The cells grew along these grooves within the hydrogel, forming fibers (bottom image). Image: Courtesy of the researchers</span></span></span></p><h2><strong>Training space</strong></h2><p>Raman’s lab at MIT aims to engineer biological materials that mimic the sensing, activity, and responsiveness of real tissues in the body. Broadly, her group seeks to apply these bioengineered materials in areas from medicine to machines. For instance, she is looking to fabricate artificial tissue that can restore function to people with neuromuscular injury. She is also exploring artificial muscles for use in soft robotics, such as muscle-powered swimmers that move through the water with fish-like flexibility.</p><p>Raman has previously developed what could be seen as gym platforms and workout routines for lab-grown muscle cells. She and her colleagues designed a <a href="https://news.mit.edu/2023/wobbly-gel-mat-trains-muscle-cells-work-together-1020" target="_blank">hydrogel “mat”</a> that encourages muscle cells to grow and fuse into fibers without peeling away. She also derived a way to “exercise” the cells by genetically engineering them to twitch in response to pulses of light. And, her group has come up with ways to direct muscle cells to grow in long, parallel lines, similar to natural, striated muscles. However, it’s been a challenge, for her group and others, to design artificial muscle tissue that moves in multiple, predictable directions.</p><p>“One of the cool things about natural muscle tissues is, they don’t just point in one direction. Take for instance, the circular musculature in our iris and around our trachea. And even within our arms and legs, muscle cells don’t point straight, but at an angle,” Raman notes. “Natural muscle has multiple orientations in the tissue, but we haven’t been able to replicate that in our engineered muscles.”</p><h2><strong>Muscle blueprint</strong></h2><p>In thinking of ways to grow multidirectional muscle tissue, the team hit on a surprisingly simple idea: stamps. Inspired in part by the classic Jell-O mold, the team looked to design a stamp, with microscopic patterns that could be imprinted into a hydrogel, similar to the muscle-training mats that the group has previously developed. The patterns of the imprinted mat could then serve as a roadmap along which muscle cells might follow and grow.</p><p>“The idea is simple. But how do you make a stamp with features as small as a single cell? And how do you stamp something that’s super soft? This gel is much softer than Jell-O, and it’s something that’s really hard to cast, because it could tear really easily,” Raman says.</p><p>The team tried variations on the stamp design and eventually landed on an approach that worked surprisingly well. The researchers fabricated a small, handheld stamp using high-precision printing facilities in MIT.nano, which enabled them to print intricate patterns of grooves, each about as wide as a single muscle cell, onto the bottom of the stamp. Before pressing the stamp into a hydrogel mat, they coated the bottom with a protein that helped the stamp imprint evenly into the gel and peel away without sticking or tearing.</p><p>As a demonstration, the researchers printed a stamp with a pattern similar to the microscopic musculature in the human iris. The iris comprises a ring of muscle surrounding the pupil. This ring of muscle is made up of an inner circle of muscle fibers arranged concentrically, following a circular pattern, and an outer circle of fibers that stretch out radially, like the rays of the sun. &nbsp;Together, this complex architecture acts to constrict or dilate the pupil.</p><p>Once Raman and her colleagues pressed the iris pattern into a hydrogel mat, they coated&nbsp;the mat with cells that they genetically engineered to respond to light. Within a day, the cells fell into the microscopic grooves and began to fuse into fibers, following the iris-like patterns and eventually growing into a whole muscle, with an architecture and size similar to a real iris.</p><p>When the team stimulated the artificial iris with pulses of light, the muscle contracted in multiple directions, similar to the iris in the human eye. Raman notes that the team’s artificial iris is fabricated with skeletal muscle cells, which are involved in voluntary motion, whereas the muscle tissue in the real human iris is made up of smooth muscle cells, which are a type of involuntary muscle tissue. They chose to pattern skeletal muscle cells in an iris-like pattern to demonstrate the ability to fabricate complex, multidirectional muscle tissue.</p><p>“In this work, we wanted to show we can use this stamp approach to make a ‘robot’ that can do things that previous muscle-powered robots can’t do,” Raman says. “We chose to work with skeletal muscle cells. But there’s nothing stopping you from doing this with any other cell type.”</p><p>She notes that while the team used precision-printing techniques, the stamp design can also be made using conventional tabletop 3D printers. Going forward, she and her colleagues plan to apply the stamping method to other cell types, as well as explore different muscle architectures and ways to activate artificial, multidirectional muscle to do useful work.</p><p>“Instead of using rigid actuators that are typical in underwater robots, if we can use soft biological robots, we can navigate and be much more energy-efficient, while also being completely biodegradable and sustainable,” Raman says. “That’s what we hope to build toward.”</p><p>This work was supported, in part, by the U.S. Office of Naval Research, the U.S. Army Research Office, the U.S. National Science Foundation, and the U.S. National Institutes of Health.</p></body></html>

MIT engineers grew an artificial, muscle-powered structure that pulls both concentrically and radially, much like how the iris in the human eye acts to dilate and constrict the pupil. Image: Courtesy of the researchers

MIT engineers developed a way to grow artificial tissues that look and act like their natural counterparts.

Artificial muscle flexes in multiple directions, offering a path to soft, wiggly robots

A detailed comparison of Orca Slicer vs Cura, two leading 3D printing slicers, evaluating slicing algorithms, features, usability, and real-world print results

Orca Slicer vs. Cura: A Technical and Practical Comparison

In this episode, we discuss how Harvard researchers cracked the code of 3D printing “shapeshifting” materials and why their efforts lay the groundwork for other innovations in the material science field.

Podcast: 3D Printing Robot Muscles

<html><head></head><body><p>There is a rising demand for smaller, thinner, and stretchable electronics to bring the innovations of tomorrow to life. In response, electronics manufacturing is adapting to meet these new requirements across industries. Flexible hybrid electronics (FHE), in particular, are notable for their capacity to bend and stretch without compromising the integrity of the electronic circuits, while enabling rapid prototyping.</p><h2 id="isPasted">What are flexible hybrid electronics?</h2><p>Flexible hybrid electronics combine the best of printed and traditional electronics to create electronics that can bend, stretch, and conform to their environment. They are characterized by the combination of printed, conductive interconnects, flexible or stretchable substrates, and mounted components. This allows for devices that are not only lightweight and flexible, but also highly functional, enabling <a href="https://www.voltera.io/applications">new applications</a> in fields such as healthcare, consumer electronics, automotive, and beyond.</p><p>Printable and flexible hybrid electronics open new doors for industries that require flexible, biocompatible, conformable, and stretchable devices. With advancements in materials and manufacturing processes, FHE offers a tremendous impact for <a href="https://www.voltera.io/use-cases/industries">industries</a> creating wearable devices, flexible displays, and even implantable electronics that can stretch with the body or adapt to irregular surfaces, among many others.</p><h2>Key components of flexible hybrid electronics</h2><p>The combination of flexible materials and rigid components makes flexible hybrid electronics unique from printed electronics or traditional rigid PCBs. FHEs integrate the advantages of flexible substrates with the robustness of conventional rigid electronic components and integrated circuits (IC), allowing researchers and engineers to customize electronics for their research, applications, and products.</p><h3>Substrates for FHEs</h3><p id="isPasted">What makes FHEs unique from other types of electronics is their use of substrates that are flexible and stretchable. <a href="https://store.voltera.io/products/pet-5-sheets?_pos=6&amp;_fid=65f88ddf8&amp;_ss=c">Polyethylene terephthalate (PET)</a> is commonly used for FHEs because it is cost-effective, durable, and flexible. However, <a href="https://store.voltera.io/products/intexar-tpu-5-sheets?_pos=7&amp;_fid=65f88ddf8&amp;_ss=c">thermoplastic polyurethane (TPU)</a>, <a href="https://store.voltera.io/products/polyimide-5-sheets?_pos=8&amp;_fid=65f88ddf8&amp;_ss=c">polyimide (PI)</a>, <a href="https://na.industrial.panasonic.com/products/electronic-materials/printed-and-flexible-hybrid-materials/lineup/beyolex-stretchable-circuit-materials" target="_blank">BEYOLEX</a>, and even novel substrates can offer different advantages, like biocompatibility or increased stretchability.&nbsp;</p><p>Some common substrate suppliers include (but are not limited to):</p><ul><li><a href="https://na.industrial.panasonic.com/products/electronic-materials/printed-and-flexible-hybrid-materials" target="_blank">Panasonic</a></li><li><a href="https://normandy-coating.com/en/" target="_blank">Normandy Coating</a></li><li><a href="https://www.dupont.com/electronics-industrial/printed-circuit-boards.html" target="_blank">Dupont</a></li><li><a href="https://polyonics.com/Resources/about-our-products.php#" target="_blank">Polyonics</a></li></ul><h3 id="isPasted">Conductors and interconnects for FHEs</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741788721796-67575c5215dd04c49acc860c_67575b0cbddec4287e182d8d_printing-conductive-copper-ink-flexible-hybrid-electronics.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper" id="isPasted">Printing copper ink</a></span></span></span></p><p id="isPasted">Conductive inks are printed on flexible substrates to create electrical connections between components in FHEs. These inks are often flexible and/or stretchable to maintain conductivity, even when the substrate is bent, twisted, or stretched. Ink is printed via printing processes such as direct ink writing, <a href="https://www.voltera.io/blog/introduction-inkjet-technology?srsltid=AfmBOooLgmtxfhJnJcFE6HwnMhtaAIAZc-sEWeeArH1babbH5SFoRI7f">inkjet printing</a>, and aerosol printing. <a href="https://www.voltera.io/blog/screen-printing-direct-ink-writing-printed-electronics">Direct ink writing</a>, in particular, ensures that ink is only applied where it is needed which eliminates unnecessary material waste.&nbsp;</p><p>Some common ink suppliers for FHE include (but are not limited to):</p><ul><li><a href="https://www.acimaterials.com/products/" target="_blank">ACI Materials&nbsp;</a></li><li><a href="https://www.celanese.com/" target="_blank">Celanese</a></li><li><a href="https://www.copprint.com/products/" target="_blank">Copprint</a></li><li><a href="https://www.creativematerials.com/products" target="_blank">Creative Materials</a></li><li><a href="https://www.elantas.com/europe/products/printed-electronics/products.html" target="_blank">Elantas</a></li><li><a href="https://www.henkel-adhesives.com/ca/en/products/industrial-coatings/inks-coatings.html" target="_blank">Henkel</a></li><li><a href="https://www.heraeus-group.com/en/heraeus-businesses/#electronics" target="_blank">Heraeus</a></li><li><a href="https://novacentrix.com/" target="_blank">Novacentrix</a></li><li><a href="https://vfp-ink-technologies.com/functionnal-decorative-inks-varnishes/" target="_blank">VFP</a></li></ul><h3>Components for FHEs</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741788785128-67575c5215dd04c49acc8655_675759a4c441da78918b7d60_flexible-hybrid-electronics-printed-pcb.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><a href="https://www.voltera.io/use-cases/white-papers/printing-flexible-pcb-silver-ink-pet" id="isPasted">Flexible printed circuit</a></span></span></span></p><p id="isPasted">Flexible hybrid electronics use traditional components such as silicon chips or resistors. Thinned silicon dies are often used in FHEs to make circuits smaller, lighter, and more adaptable to flexible applications. Components are mounted onto the printed conductive paths, forming the <a href="https://www.idtechex.com/en/research-article/flexible-hybrid-electronics-future-of-flexible-printed-circuit-boards/20603" target="_blank">hybrid nature of FHEs</a>. Components are often coated with an encapsulant like epoxy resins, silicone, or polyimide to protect against corrosion and contaminants, and help to reinforce components on the substrate when flexed.</p><h2>Flexible hybrid electronics vs printed electronics vs flexible printed circuit boards</h2><p>Other types of electronics are similar to flexible hybrid electronics, so you might be wondering, how do flexible hybrid electronics compare to printed electronics (PE) and <a href="https://www.voltera.io/use-cases/applications/flexible-pcbs">flexible printed circuit boards</a> (FPCB)? Each type is uniquely positioned to tackle different electronics applications, so understanding the differences is key to choosing the right solution for different projects.&nbsp;</p><h3>Comparison of FHE vs PE vs FPCB</h3><table><thead><tr><th>Flexible hybrid electronics (FHE)</th><th>Printed electronics (PE)</th><th>Flexible printed circuit boards (FPCB)</th></tr></thead><tbody><tr><td>Flexible/stretchable substrate</td><td>Flexible/stretchable substrate</td><td>Flexible (usually polyimide) substrate</td></tr><tr><td>Conductive ink (printed)</td><td>Conductive ink (printed)</td><td>Etched copper or laminated foil interconnects</td></tr><tr><td>Rigid components</td><td>Printed components</td><td>Rigid components</td></tr><tr><td>Limitation: Mechanical stress could cause material fatigue or dislodge components over time</td><td>Limitation: Still many years out from mass manufacturing fully printed electronics</td><td>Limitation: Requires subtractive manufacturing to create conductive traces, which wastes material and causes excess pollution</td></tr><tr><td>Advantage: Thinner and more flexible than traditional PCBs, low-cost for small production runs</td><td>Advantage: All elements are thin, flexible, and/or stretchable</td><td>Advantage: Utilizes existing PCB manufacturing lines for higher-value devices</td></tr></tbody></table><h2>Future outlook for flexible hybrid electronics</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741788871734-67575c5215dd04c49acc8696_67575b836033c6402dc43a27_gold-ecg-electrode-bioelectronics-future.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu" id="isPasted">Printed ECG electrode</a></span></span></span></p><p id="isPasted">Technological innovations are continually shaping the way industries approach electronics, and as a result, there is a growing demand for FHEs. According to<a href="https://www.idtechex.com/en/research-report/flexible-hybrid-electronics-2024-2034/950" target="_blank">&nbsp;IDTechEx</a>, the flexible hybrid electronics market is projected to reach $1.8 billion USD by 2034.&nbsp;</p><p>The main industries positioned for growth in the flexible hybrid electronics market are:</p><ul><li><a href="https://www.voltera.io/applications/bioelectronics">Bioelectronics</a>: FHEs enable flexible, biocompatible devices like biosensors, electrodes, and wearable health monitors, improving personalized medicine and real-time patient care.</li><li><a href="https://www.voltera.io/applications/wearables">Wearables</a>: FHEs make smart devices, fitness trackers, and e-textiles lighter, more comfortable, and more durable.</li><li><a href="https://www.voltera.io/applications/printed-batteries">Printed batteries</a>: FHEs support the development of lightweight, flexible printed batteries, creating energy storage solutions ideal for small, portable, and wearable devices.</li><li><a href="https://www.voltera.io/applications/printed-antennas">Antennas</a>: FHE-based antennas enable high-performance, bendable communication systems for 5G, IoT devices, and compact wearables.</li></ul><p>By merging the best features of printed electronics and traditional electronics, FHEs offer the versatility to meet the growing demand for smaller, thinner, and more flexible devices without compromising on performance or reliability. FHE technologies will drive the next wave of electronics, offering solutions that are functional, comfortable, and integrated seamlessly into everyday life.</p><p>Take a look at some of Voltera's in-house FHE projects:</p><ul><li><a href="https://www.voltera.io/application-whitepapers/printing-electroluminescent-ink-paper-pet">Printing Electroluminescent Ink on Paper and PET</a></li><li><a href="https://www.voltera.io/application-whitepapers/printing-multilayer-flexible-membrane-keyboard-conductive-silver-ink-dielectric-ink-pet">Printing a Flexible Membrane Keyboard with Conductive Silver Ink and Dielectric Ink on PET</a></li></ul><p>Want the latest news in printed electronics? <a href="https://share.hsforms.com/1BPx4J9lvQ7-8px6MtaXF0w34u2a?__hstc=13863464.78a9a3421439726983598cbbe37f8a6e.1724398561694.1739442788711.1741782731386.30&amp;__hssc=13863464.1.1741782731386&amp;__hsfp=2596353879" target="_blank" rel="noopener noreferrer">Subscribe to Voltera's newsletter</a>. If you have questions about your PCB printing needs, you can get in touch with Voltera at <a href="mailto:sales@voltera.io">sales@voltera.io</a> or <a href="https://www.voltera.io/book-a-meeting">book a meeting</a>.</p></body></html>

Flexible hybrid electronics (FHE) enable bendable, stretchable devices for healthcare, consumer tech, and automotive. Explore how electronics manufacturers are leveraging FHE to meet new requirements across industries.

What are Flexible Hybrid Electronics (FHE)?

This article will examine how 3D printing can be integrated across different levels of education and how it helps equip students with essential skills for their future workplace.

3D Printing in Education: From Classroom to the Workplace

<html><head></head><body><h2 id="isPasted">INJECTION MOLDING WITH 3D PRINTED MOLDS</h2><h3>WHEN DOES IT MAKE SENSE?</h3><ul><li>When it is early stages of product development where the design changes frequently or very low sample volume production is needed (i.e., 100 parts).</li><li>When there are requirements for precision, repeatability, better physical and thermal part properties than the 3D printed parts.</li><li>To eliminate secondary operations commonly experienced in 3D printing.&nbsp;</li></ul><h3>POTENTIAL PARTS:</h3><ul><li>Eyeglass frame</li><li>Shaft bushing</li><li>Mask strap</li><li>Shield clip</li><li>Golf ball markers and tees</li><li>Small miniature toys</li></ul><p><br></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741286844076-1741286844076.png" alt="APSX-PIM 3D printed molds" class="fr-fic fr-dii"></p><p><br></p><h3>INTRODUCTION</h3><p>The use of 3D printed molds in injection molding has gained traction as an innovative approach for rapid prototyping and small-batch production. Compared to traditional metal molds, 3D printed molds provide a cost-effective and flexible solution, enabling manufacturers and designers to quickly test and iterate product designs.</p><p><br></p><h3>ADVANTAGES OF 3D PRINTED MOLDS</h3><h4 data-pm-slice="1 1 []">1.&nbsp;<strong>Cost Efficiency</strong></h4><p>Traditional mold-making requires expensive tooling and machining, making small production runs prohibitively costly. 3D printing allows for significantly lower costs, especially for prototypes and low-volume production, eliminating the need for expensive metal tooling.</p><h4>2.&nbsp;<strong>Rapid Prototyping</strong></h4><p>With 3D printing, molds can be created in a matter of hours or days rather than weeks. This enables faster design validation and iteration, shortening the overall product development cycle.</p><h4>3.&nbsp;<strong>Design Flexibility</strong></h4><p>Unlike conventional mold-making, which has geometric constraints, 3D printed molds allow for intricate and complex designs. This makes them ideal for producing custom and highly detailed parts.</p><h4>4.&nbsp;<strong>Accessibility</strong></h4><p>Many businesses and individuals can now access 3D printing technologies at a fraction of the cost of traditional manufacturing, opening up new opportunities for small-scale production and niche markets.</p><p>The&nbsp;3D printed mold can make the product development process little bit faster and reduce the initial costs compared to 3D printing. Plus,&nbsp;it improves the product quality with functional prototypes.</p><p>However, you may still need to use CNC machining or hand sanding to prepare the 3D printed mold. The mold pairs need to align perfectly during the clamping stage. Due to surface imperfections, the secondary operations may be required. If you need holes smaller than 0.5mm on the mold that would also require a secondary operation. In small mold sizes (6" by 4.8"), there is not much cost difference between a 3D printed mold and a CNC machined aluminum mold</p><p><br></p><h3>LIMITATIONS</h3><p>While 3D printed molds offer numerous benefits, they also have some drawbacks that should be considered:</p><ul data-spread="false"><li><p><strong>Durability Concerns</strong>: 3D printed molds may degrade faster than metal molds, especially under high injection pressures and temperatures.</p></li><li><p><strong>Surface Finish</strong>: Parts molded from 3D printed molds may require post-processing to achieve the desired surface quality.</p></li><li><p><strong>Production Volume</strong>: Best suited for small production runs; high-volume manufacturing still favors traditional molds due to longevity concerns.</p></li><li><p><strong>Material Compatibility</strong>: Some plastics, such as high-temperature thermoplastics, may not be suitable for 3D printed molds due to heat resistance limitations.</p></li></ul><p><br></p><h3>REQUIRED EQUIPMENT</h3><h3>SLA 3D Printer:&nbsp;</h3><p>SLA printers are a better choice compared to FDM. Smoother surface finish and higher precision. Chemically bonded, dense and isotropic. You can create surface finish texture-out of the SLA printing. <a href="https://formlabs.com/3d-printers/form-3/" target="_blank">The Form 3</a> from Formlab can be a good option to use.</p><p><br></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741286843450-1741286843450.png" alt="Form 3 from Formlab" class="fr-fic fr-dii"></p><p><br></p><h3>MATERIALS SUITABLE FOR 3D PRINTED MOLDS</h3><p>Choosing the right material for 3D printed molds is crucial for achieving optimal results in injection molding. Some common options include:</p><ul data-spread="false"><li><p><strong>High-Performance Resins</strong> (e.g., Formlabs Rigid 10K, Tough 2000) – Provide durability and high heat resistance, making them suitable for limited production runs.</p></li><li><p><strong>Engineering-Grade Plastics</strong> (e.g., Nylon, Polycarbonate) – Offer increased strength and wear resistance for extended mold life.</p></li><li><p><strong>Metal-Infused Polymers</strong> – Provide enhanced thermal conductivity and durability, improving mold longevity and cooling efficiency.</p></li></ul><p><br></p><p><br></p><h3>IINJECTION MOLDING MACHINE:&nbsp;</h3><p>To get good and consistent parts, the injection molding machine should have precise process control for the injection pressure, plastic temperature, and clamp force. The <a href="https://apsx.com/desktop-injection-molding-machine" target="_blank">APSX-PIM injection machine</a> provides the best value for injection molding with 3D printed molds. The precision and the pricing are hard to match.&nbsp;</p><p><a href="https://apsx.com/how-to-use-apsx-pim-injection-machine" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741286843601-1741286843601.png" alt="How to use APSX-PIM" class="fr-fic fr-dii"></a></p><p><br></p><h3>PROCESS STEPS</h3><ul><li><h3>Mold Design: &nbsp;</h3></li></ul><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741286843377-1741286843377.png" alt="How to design a mold" class="fr-fic fr-dii"></p><p><br></p><p>Any CAD software is ok to use to design the 3D printed mold. There is a&nbsp;<a href="https://apsx.com/designing-the-mold-in-cad-fusion-360" target="_blank">guideline</a> available on our website.&nbsp;Follow these additional guidelines below:</p><p>Add 2-5 degrees draft angle, air vents (0.05mm) and use larger gates.</p><p>Design one side flat and other side carrying the design to eliminate the misalignment risk.</p><p>Have walls greater than 1-2mm and features larger than 0.5mm.</p><p><br></p><ul><li><h3>3D Printing: &nbsp;</h3></li></ul><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741286843747-1741286843747.png" alt="3D printing injection molds" class="fr-fic fr-dii"></p><p><br></p><p>It is suggested using an SLA type 3D printer:</p><p>The material needs to withstand clamping, injection pressure, and high temperatures. There are available options in the market for the 3D printed material:</p><p>Formlab has <a href="https://formlabs.com/store/rigid-10k-resin/" target="_blank">Rigid 10K</a> or&nbsp;<a href="https://formlabs.com/store/high-temp-resin/" target="_blank">High Melt</a>. Asiga has&nbsp;<a href="https://www.asiga.com/media/main/files/materials/Asiga%20Material%20Handbook%20-%20Manufacturing%20en_US.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">FusionGray</a>. Markforged has&nbsp;<a href="https://markforged.com/materials/plastics/onyx" target="_blank">Onyx</a>.&nbsp;</p><p>Printing in 50-micron layer is a good approach.</p><p>Preparing the mold, including the <a href="https://formlabs.com/blog/introduction-post-curing-sla-3d-prints/" target="_blank">"post-curing"</a> process. Typically a CNC machining or hand sanding operation is required after the 3D printing.&nbsp;</p><p>Larger the mold size, the more difficult it is to process for injection molding.</p><p><br></p><ul><li><h3>Mold Installation: &nbsp;</h3></li></ul><p><a href="https://youtu.be/MQY_lk05r1g?si=Z9bzHjBhWMhdXK_4" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741286843634-1741286843634.png" alt="How to install a 3D printed mold" class="fr-fic fr-dii"></a></p><p><br></p><p>There are benefits to use a&nbsp;<a href="https://apsx.com/3d-printed-insert-mold-holder-for-apsx-pim" target="_blank">aluminum mold holder (MUD)</a> along with the 3D printed molds:</p><p>It adds stability to the 3D printed mold.</p><p>It increases the life of the 3D printed mold by helping it to cool faster.</p><p><br></p><ul><li><h3>Injection Molding: &nbsp;</h3></li></ul><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741286844009-1741286844009.png" alt="APSX-PIM setting for 3D printed molds" class="fr-fic fr-dii"></p><p><br></p><p>The suggested settings for the PP material can found in the picture above. Guidlines below for some injected material and injection parameters: high melt flow rate is better - injecting PP or TPE are the best options</p><ul><li>Material | Temperature | Injection pressure | Cycle time | Mold life</li><li>PP | 220C | 100BAR | 150sec 100cycles&nbsp;</li><li>HDPE | 225C | 150BAR | 120sec | 100cycles</li><li>ABS | 220C | 95BAR | 160sec | 60cycles</li><li>PC/ABS | 240C | 95BAR | 160sec | 60cycles</li><li>Delrin (POM) | 180C | 150BAR | 120sec | 60cycles</li><li>Nylon | 260C | 80BAR | 120sec | 50cycles</li></ul><p>The mold life is a function of the part design, injection material, and molding parameters.</p><p>The part design includes the wall thickness and part volume. Thin walls and large part volume requires higher pressures and clamping. There may be cracks on the mold corners and detailed part features.</p><p>Injection material determines the flow rate and processing temperature. Lower flow rate and high processing temperatures increase the required temperature. The mold material becomes very brittle quickly if you do not allow long enough cooling time in between cycles.&nbsp;</p><p>The need for a silicone release agent (Sprayon or Slide brands) for sticky materials such as TPU and Polycarbonate (PC) may damage the mold.&nbsp;</p><p><br></p><ul><li><h3>Air Cooling: &nbsp;</h3></li></ul><p>Using an aluminum mold holder (MUD) increases the life of the 3D printed mold by helping it to cool faster. APSX-PIM offers one and uses a variable speed fan for cooling the mold.</p><p><br></p><ul><li><h3>Part Ejection: &nbsp;</h3></li></ul><p>Using a large draft angle (2-5 degrees) helps pull the part out of the mold at the end of the injection cycle. As an option, <a href="https://youtu.be/VazxnBSpxJ0?si=V4Dw33RrK_guuyEl" target="_blank">an ejector mechanism can be added</a> to the mold for automatic injection molding cycle mode. Since the mold life is not too long, adding additional costs for the ejector pins may not make sense.</p><p><br></p><h3>Best Practices for Using 3D Printed Molds</h3><p>To maximize the effectiveness of 3D printed molds, follow these best practices:</p><ul data-spread="false"><li><p><strong>Optimize Mold Design</strong>: Ensure adequate wall thickness, reinforcement, and draft angles for improved durability and easier part ejection.</p></li><li><p><strong>Enhance Surface Finish</strong>: Sanding, polishing, or applying coatings can improve mold longevity and part quality.</p></li><li><p><strong>Regulate Injection Parameters</strong>: Use lower injection pressures and temperatures to extend mold lifespan and prevent deformation.</p></li><li><p><strong>Incorporate Cooling Features</strong>: If possible, integrate cooling channels or use heat-resistant materials to enhance mold performance.</p></li><li><p><strong>Test and Iterate</strong>: Conduct trial runs and refine mold designs as necessary to achieve the best results.</p></li></ul><h3>Conclusion</h3><p>3D printed molds offer a compelling alternative for injection molding applications, particularly for prototyping and low-volume production. While they are not a direct replacement for metal molds in high-volume manufacturing, they provide an affordable, flexible, and efficient solution for product development. By understanding their advantages, limitations, and best practices, businesses and designers can leverage 3D printed molds to innovate and streamline their manufacturing processes.</p></body></html>

3D printed molds offer a compelling alternative for injection molding applications, particularly for prototyping and low-volume production. 

INJECTION MOLDING GUIDELINES WITH 3D PRINTED MOLDS

<html><head></head><body><p>3D printing, also known as additive manufacturing, is a relatively new but rapidly maturing production method that is transforming how products are developed and manufactured across industries like healthcare, aerospace, energy, and electronics. The technology, which dates back to the 1980s, is based on the principle that components are constructed additively rather than subtractively, which <a href="https://xtpl.com/understanding-the-additive-manufacturing-process-from-design-to-finished-product/">results in benefits</a> like greater design freedom and less material waste.&nbsp;</p><p>Historically, 3D printing has primarily been used as a prototyping technology, allowing for the rapid iteration of physical prototypes from a 3D CAD model without the need for any costly tooling. Today, however, the technology is increasingly being used for end-use applications in addition to prototyping, as the quality of the manufacturing processes improves and material options continue to grow.&nbsp;</p><p>When talking about 3D printing materials, you’d be forgiven for first thinking of spools of thermoplastic filament or vats of photopolymer resin. While these are among the more common types of 3D printing consumables, there are actually a wide range of additive manufacturing processes that require different types of materials, from thermoplastic filaments, to photopolymer resins, to polymer, ceramic, and metal powders, to nanomaterials.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741248119212-rob-wingate-nHRfTeqAxjs-unsplash.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Photo by Rob Wingate on Unsplash</span></span></span></p><h2>What Are Nanomaterials?&nbsp;</h2><p>Today, nanomaterials are at the frontier of additive manufacturing technology as they allow for the production of parts with superior properties compared to neat materials. In the simplest terms, nanomaterials are made up of a matrix material, such as a polymer, which is embedded with nanoparticles (measuring between 1 and 100 nanometres in diameter). The nanoparticles used in nanomaterials or nanocomposites can vary and the type of nanoparticle plays a central role in determining the properties and functions of the material in question.&nbsp;</p><p>For example, there are different categories of nanomaterials including: carbon-based nanomaterials that are filled with carbon nanotubes or graphene and are notable for their conductive properties; metallic nanomaterials with silver or gold nanoparticles; semiconductor nanomaterials like quantum dots; and ceramic nanocomposites with insulating and strengthening properties. Typically, these nanoparticles are contained within a matrix material of polymer, metal, or ceramic, which can be used in various 3D printing technologies.</p><h2>3D Printing Nanomaterials: Challenges and Outlook</h2><p>Unlike more conventional nanomaterial production methods, like chemical vapour deposition (CVD), 3D printing offers a number of benefits, including more complex geometries, greater customization, and more control over material distribution. There are several different additive manufacturing processes that can use nanomaterials, including directed energy deposition (DED), fused filament fabrication (FFF), powder bed fusion (PBF), photopolymerization processes like stereolithography (SLA) and digital light processing (DLP), and material jetting.&nbsp;</p><p>Among the main challenges of bringing nanomaterial 3D printing more into the mainstream is achieving uniform dispersions of nanoparticles in the matrix material. This is a challenge across different additive manufacturing processes, including extrusion, resin, and material jetting technologies, since nanoparticles can agglomerate in the matrix, which can result in inconsistent results and uneven material properties. If you can imagine a 3D printed wound dressing where the antimicrobial properties are concentrated in just one area, you can understand the severity of this challenge. Other challenges are associated with how the addition of nanoparticles can alter the printability of materials, whether the viscosity of an ink, the curing properties of a resin, or the abrasiveness of a filament. On top of that, the processing conditions, such as temperature and speed, need to be precisely controlled in the 3D printing process to prevent the degradation of nanomaterial properties.&nbsp;</p><p>Presently, the use of nanomaterials or nanocomposites in 3D printing technologies is still largely limited to the research realm. However, the potential applications for the materials in the 3D printing process are highly promising. For example, integrating silver nanoparticles into a 3D printed structure could add antimicrobial properties useful for applications like medical implants and wound dressing.[1] Graphene nanoparticles and carbon nanotubes, for their part, are being investigated for their ability to add conductive properties to parts made using FFF 3D printing.[2] And at a university in Oklahoma, researchers are investigating the use of flame-retardant nanoparticles in a biopolymer matrix to make certain plastics more fire resistant.[3]&nbsp;</p><p>Despite the fact that 3D printing nanomaterials is still a nascent field, there are commercialized products that integrate nanoparticles. SLA specialist Formlabs, for example, sells a nano- ceramic filled Class II biocompatible material for the dental industry. The photopolymer resin offers superior strength and wear resistance thanks to its ceramic nanoparticles.[4]&nbsp;</p><p><a href="https://xtpl.com/nanomaterials-in-3d-electronics-printing-xtpl/">Nanomaterial additive manufacturing</a> technology is also expanding into areas like microelectronics, facilitating the fabrication of complex, miniaturized components with enhanced electrical conductivity and mechanical properties using a combination of conductive and dielectric nanomaterials. Companies like XTPL are leading on this front, bringing to market a range of conductive inks and pastes as well as a precision dispensing process for creating miniaturized electrical circuits.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741248190075-andrea-g-Yc9ROfBvWEw-unsplash.jpg" style="width: 832px;" class="fr-fic fr-dib"><span class="fr-inner">Photo by Andrea G on Unsplash</span></span></span></p><h2>The Future of 3D Printing is Nanomaterials</h2><p>These applications are just the tip of the iceberg: as it advances, nanomaterial additive manufacturing can and will transform 3D printing applications in industries like healthcare, aerospace, and electronics through the development of stronger, more lightweight components as well as products with unique characteristics, like antibacterial properties, conductivity, and more.&nbsp;</p><hr><h3>Resources&nbsp;</h3><p id="isPasted"><span dir="ltr">[1] Astaneh ME, Fereydouni N. Silver Nanoparticles in 3D Printing: A New Frontier in Wound&nbsp;</span><br><span dir="ltr">Healing. ACS omega. 2024 Sep 16;9(40):41107-29.</span><br><span dir="ltr">[2] Bajpai A, Jain PK. Investigation on 3D printing of graphene and multi-walled carbon&nbsp;</span><br><span dir="ltr">nanotube mixed flexible electrically conductive parts using fused filament fabrication. Journal of&nbsp;</span><br><span dir="ltr">Materials Engineering and Performance. 2023 Jul;32(14):6319-28.</span><br><span dir="ltr">[3] OSU research focuses on improving fire safety in 3D-printed materials [Internet]. Oklahoma&nbsp;</span><br><span dir="ltr">State University, January 30, 2025.&nbsp;</span><span dir="ltr">https://news.okstate.edu/articles/engineering-architecture-</span><br><span dir="ltr">technology/2025/</span><br><span dir="ltr">osu_research_focuses_on_improving_fire_safety_in_3d_printed_materials.html#h_6010598121</span><br><span dir="ltr">71738267359042</span><br><span dir="ltr">[4] Formlabs’ Premium Teeth Resin Receives FDA 510(k) Clearance for Temporary Crowns and</span><br><span dir="ltr">Bridges [Internet]. Formlabs, August 6, 2024.&nbsp;</span><br><span dir="ltr">https://dental.formlabs.com/company/press/premium-teeth-resin-receives-fda-clearance-</span><br><span dir="ltr">temporary-crowns-and-bridges/</span></p></body></html>

3D printing materials filled with precise quantities of nanoparticles are making a profound impact on industries like electronics, healthcare, and aerospace

New Horizons in Additive Manufacturing Technology: Utilizing Nanomaterials in 3D Printing

In this episode, we chat about the efforts of researchers at ETH Zurich to dehumidify indoor spaces using waste material in an effort to reduce energy consumption & help Switzerland hit their net zero emissions goal by 2050!

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