<p>As 3D printing continues to be integrated into workflows in industries like manufacturing and healthcare, cybersecurity in additive manufacturing is becoming increasingly crucial.</p><p>Recently, we dove into the <a href="https://ultimaker.com/learn/security-in-3d-printing-key-factors-to-consider/">key factors to consider in 3D printing security.</a> In this article, we’ll provide a high-level overview of the best practices from a network perspective down to the individual printers.</p><h2>Network and ecosystem security</h2><p>Whether it’s unauthorized access, data breaches, or malicious firmware modifications, users must stay vigilant. Keeping printers, networks, and digital workflows secure is essential to prevent cyber threats.</p><h3>Network segmentation and firewalls</h3><p>Keeping your 3D printers on a separate VLAN or dedicated network, along with implementing a firewall to restrict external access to the network, are efficient methods to prevent unauthorized access from other devices.</p><p>UltiMaker printers, such as the S series and Factor series, come equipped with <a href="https://support.makerbot.com/s/article/1667412438827">built-in firewall capabilities</a> and allow administrators to activate them to ensure that only trusted devices can communicate with the printers.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1743062461454-Screenshot-2025-02-17-at-10.webp" style="width:100%px" class="fr-fic fr-dib" /></p><h3>Zero trust approach</h3><p>A security philosophy that is widely known and adopted across multiple industries, it refers to the implementation of role-based access control (RBAC) and multi-factor authentication (MFA) for cloud-based management systems.</p><p>Through UltiMaker Digital Factory, administrators can assign roles (e.g. admin, member, guest) to users, ensuring that only authorized personnel have access to specific functions. Additionally, the two-factor authentication feature enhances security by adding an extra layer of verification.</p><p>As part of our vertically integrated ecosystem, the UltiMaker Cura Enterprise slicer is installed to prevent non-administrator users from accessing the installation of UltiMaker Cura (its basic files or directories). As a result, the “side loading” of plugins is blocked.</p><h2>Data protection and access control</h2><p>Now let’s look at how we can safeguard sensitive print files, restrict unauthorized access, and monitor system activity to prevent breaches.</p><h3>Encrypted communications</h3><p>Businesses should ensure that print files and G-code are transmitted using encrypted protocols. For UltiMaker, all cloud-based data is transmitted using HTTPS (TLS 1.2) connections with industry-standard 2048-bit RSA encryption, safeguarding data transfer.</p><h3>User authentication and permissions</h3><p>Assigning different levels of permissions based on user roles ensures that only authorized individuals can access and control your 3D printers. This helps safely manage print jobs based on assigned roles:</p><ul><li><strong>Administrators: </strong>can manage printers, users and workflows.</li><li><strong>Operators:</strong> can start and monitor prints but cannot modify critical settings.</li><li><strong>Guests:</strong> may have view-only access, ensuring that they cannot interfere with production.</li></ul><p>Keep in mind that enabling MFA will help prevent unauthorized logins even if user passwords are compromised.</p><h3>Audit logs and monitoring</h3><p>Keeping track of who accessed or modified parameters in a 3D printing network is also integral in detecting security breaches. UltiMaker Digital Factory, for example, provides detailed activity logs, allowing administrators to monitor:</p><ul><li><strong>Who</strong> started or modified a print job.</li><li><strong>When</strong> firmware or software settings were changed.</li><li><strong>Unusual</strong> login attempts or unauthorized access.</li></ul><p>Audit logs help detect anomalies and enable businesses to respond quickly to potential threats. By implementing real-time monitoring and alters, users can proactively manage security risks in their 3D printing environment.</p><h2>Software and firmware security</h2><p>Any system is only as strong as its weakest link.To keep both network and printers protected, users should ensure that firmware and software solutions are always up-to-date.</p><h3>Regular firmware and software updates</h3><p>As new vulnerabilities are discovered, frequent firmware updates will ensure that not only will you benefit from the latest features but that you will also receive the newest security patches. Users are always encouraged to keep their devices updated to benefit from the latest protections.</p><p>On a similar note, users should always opt for trusted, verified slicing software (such as <a href="https://ultimaker.com/software/ultimaker-cura/">UltiMaker Cura</a>) to prevent maliciously embedded code and ensure that firmware updates are verified using cryptographic signatures so that only authorized firmware is installed on the printers.</p><h2>Physical and printer-level security</h2><p>Securing physical access is just as important as protecting the network and software.</p><p>Other than physically restricting printers in a dedicated work area with limited access (e.g. via security badges), an easier and more secure feature is the option to set a PIN-code on each machine to restrict access to the printer settings.</p><p>Available on the UltiMaker S series and Factory series printers, this option can be enabled either via the printer’s display or through Digital Factory.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1743062485010-DF-1.webp" style="width:100%px" class="fr-fic fr-dib" /></p><h2 id="isPasted">Staying secure with the UltiMaker Ecosystem</h2><p>We remain committed to supporting open system solutions and allowing our users freedom of choice by never locking out functionality behind mandatory authorizations controls or limiting user autonomy.</p><p>We also believe that our vertically integrated ecosystem provides a secure comprehensive solution that is designed for industrial environments.</p><p>If you want to stay ahead of cyber threats and keep your 3D printing environment secure, explore <a href="https://ultimaker.com/software/ultimaker-digital-factory/">UltiMaker’s Digital Factory </a>and our secure ecosystem today to take control of your 3D printing workflow.</p>

In this article, we’ll provide a high-level overview of the best practices from a network perspective down to the individual printers.

Security in 3D Printing: How to Stay Protected from Cybersecurity Threats

<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>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?

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

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><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

<h2 id="isPasted">3D printer lifespan: Factors to consider</h2><p>While the first step any user should do before running their 3D printer for the first time should be to read the user manual, there are some other factors to consider that are generally applicable regardless of the 3D printer you’re using.</p><h2>3D printer usage</h2><p>The frequency and intensity of use can dramatically affect the lifespan of a 3D printer. Printers that run continuously, such as in production environments or 3D print farms, are subject to greater mechanical stress which can accelerate the wear on belts, gears, hot ends, and other components.</p><p>That’s not to say that an idle printer will not encounter any issues if uncared for. Unused filaments improperly stored can absorb moisture which can lead to bad prints or clogging, and dust build-up in dormant machines can result in print failures when restarted.</p><h3>Some general points to consider:</h3><p><strong>Print Volume and Duration</strong>: High-volume printing or long print jobs tend to wear components faster. Regular maintenance is key and some manufacturers even provide guides on how often you should service your printer's components, usually measured in printing hours.</p><p><strong>Materials Used:</strong> Some materials like carbon-fiber filaments are more abrasive and can wear down nozzles or drive gears more quickly. Accounting for the material type used can help plan out maintenance schedules.</p><p><strong>User Proficiency:</strong> Improper calibration along with wrong settings for speed, acceleration, or temperature for specific materials can lead to increased strain on the machine or very often result in bad or failed prints. Over time, these will add additional stress on the printer and can lead to breakdowns.</p><h2>Print environment</h2><p>Where you use your printer matters, as the surrounding environment plays a critical role in determining your printer’s performance. From temperature and humidity to dust and vibrations, all these factors can either help or hinder the longevity of your printer.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741155074405-life-span-1.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">When considering&nbsp;<strong>temperature&nbsp;</strong>and&nbsp;<strong>humidity</strong> we need to ensure the following:</p><ul><li><strong>Consistent temperatures:</strong> Extreme heat or cold can lead to inconsistent extrusion, warping, or layer delamination. While some printers come with dedicated enclosures and ventilation systems to mitigate this, open bed printers are more susceptible to these variations which can make printing some filaments more difficult.</li><li><strong>Humidity control</strong>: When talking about filaments, humidity is one of the key factors to monitor, as most of them are highly hygroscopic(they absorb ambient moisture) which as we previously mentioned, can cause clogging, poor layer adhesion or result in failed prints. It is important that filament rolls are stored in a low-humidity(preferably controlled) storage and that the print area is maintained at a stable temperature to help combat this issue.</li><li><strong>Consistent airflow:</strong> While many industrial or professional 3D printers such as our own UltiMaker printers come with enclosed chambers and air management systems to regulate internal temperatures and filter out fumes or particles, adequate ventilation in the room is still important. For open bed printers, you should ensure a consistent airflow by ensuring that the printer is not under a strong or direct draft(from open windows, fans or air conditioning units).</li><li><strong>Dust and contaminants:</strong> Lint, hair, or other particles can build up on the various components and lead to clogs or mechanical wear over time. Ensuring that you regularly clean your printer is the simplest and most important step to ensure that your printer remains optimal for longer.</li></ul><p>Cleaning out the build plate after each print should be considered an absolute must for any printer operation, failure to do so will often result in very poor first layer adhesion which can lead to failed prints or a slew of other issues. Check out our&nbsp;<a href="https://ultimaker.com/learn/6-key-factors-that-affect-indoor-air-quality-when-3d-printing/">6 Key Factors That Affect Indoor Air Quality When 3D Printing</a> for a more in-depth look at this topic.</p><p>Less known factors are&nbsp;<strong>vibrations and stability</strong>, often overlooked the surface you place your printer on is an important element in your 3D printer’s lifespan.</p><ul><li><strong>Solid surface:</strong> ensuring that your printer is placed on a level, stable surface will help avoid issues that are more difficult to troubleshoot such as layer misalignments or layer shifts. Especially with the higher speeds and accelerations that some printers are capable of, this factor becomes more important as it’s the main prevention against ringing(caused by resonance frequency, an interesting phenomenon that we might dive into deeper in a separate article).</li></ul><h2>Maintenance of 3D printer</h2><p>Regular maintenance is without a doubt one of the most effective ways to extend the lifespan of your 3D printer and maintain consistent print quality. While specific procedures will vary between different printer models and brands, there are a few universal tasks that every user should keep in mind.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741155094247-lifespan2.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted">Routine cleaning</h3><p>We briefly touched on the subject earlier, but cleaning extends to several other parts besides the print bed:</p><ul><li><strong>Nozzle and extruder</strong>: Periodically clean out any filament residue or blockages to ensure smooth material flow. This process typically involved removing and cleaning the nozzle or performing what’s known as a cold/hot pull.</li><li><strong>Build plate</strong>: For the majority of build plates in 3D printers, cleaning is recommended to be done using a microfibre cloth and &gt;95% isopropyl alcohol(IPA), though please note that you should ensure good ventilation and avoid inhaling the alcohol vapors.</li><li><strong>Fans&nbsp;</strong>and <strong>filters:</strong> If your printer comes with a dedicated filter, these should be replaced periodically(according to your manual) as part of a scheduled routine. Fans can cleaned out by using compressed air.</li></ul><h3>Calibration and lubrication</h3><ul><li><strong>Moving parts:</strong> Rods, lead screws or linear guide rails will typically require periodic lubrication. This will help minimize friction and ensure a smooth motion across all axis.</li><li><strong>Axis calibration:</strong> All 3D printers have a process to check and calibrate the X, Y, and Z axes. While some printers can perform this step automatically before each print, this step is critical as small misalignments can compound over time, especially in printers with multiple extruders.</li></ul><h3>Firmware and software updates</h3><p>While this is a step that is sometimes overlooked, firmware and software updates can do a lot to extend your 3D printer’s lifespan.</p><ul><li><strong>Firmware:</strong> Keeping your printer’s firmware up to date can improve reliability and security while also adding new features or performance tweaks. Without touching any of the mechanical parts, firmware updates can for example improve how the printer accelerates and decelerates during motion to reduce vibrations while maintaining speed which would improve print quality.</li><li><strong>Software:</strong> Updating your slicing software(we highly recommend&nbsp;<a href="https://ultimaker.com/software/ultimaker-cura/">Cura</a>) to the latest version, will benefit from bug fixes, optimized print profiles as well as&nbsp;<a href="https://ultimaker.com/learn/unlock-true-multi-material-printing-with-ultimaker-cura-5-3/">new functionalities</a>.</li></ul><h2>Component quality</h2><p>The quality of the components used will directly impact the quality and reliability of the end product, this applies to all devices not just 3D printers. The reason why we wanted to address this aspect as well is because with the myriad of options available on the 3D printer market, users should be able to make educated decisions to best benefit their use case.</p><p>Whether you’re a hobbyist looking to tinker and modify your printer, or a professional in search of a durable machine that can handle rigorous, high-volume usage over time, these are the factors we think you should consider that affect a printer’s lifespan.</p><h3>Frame and structural integrity</h3><ul><li><strong>Rigid construction:</strong> A sturdy frame, from aluminum or steel, helps maintain the precise alignment of moving parts. This directly impacts print accuracy and also reduces stress on mechanical components.</li></ul><h3>Motion system components</h3><ul><li><strong>Linear bearing and rails:</strong> Linear bearings and hardened steel rails ensure a smoother motion and can handle repetitive stress for longer without developing play or wobble. Cheaper options are available such as smooth rods with self-lubricating bushings or v-slot extrusions paired with Delrin/polycarbonate wheels though they tend to wear out faster and require more frequent maintenance and replacements.</li></ul><h3>Extruder and print head assembly</h3><ul><li><strong>Drive gears:</strong> extruders(whether bowden or direct drive) with high-quality metal drive gears, will grip filament more reliably and resist wear from abrasive materials(like carbon fiber, or wood-infused filaments). Common hobbyist-level 3D printers will typically use brass gears are fine for soft filaments like PLA, but will require replacement a lot more often.</li><li><strong>Nozzles and print cores:</strong> depending on the material profiles you plan to use, the nozzle material becomes an important factor, hardened steel or ruby-tipped nozzles will last longer than brass nozzles, especially when printing more abrasive filaments such as carbon fibre reinforced filaments.</li></ul><p>While there are some other quality-of-life features to consider such as sensors and monitoring systems like filament flow sensors or thermal runaway protection that add a layer of reliability, one of the most important aspects to consider when talking about component quality is&nbsp;<strong>long-term ROI.</strong></p><ul><li><strong>Cost-benefit analysis:</strong> While a printer with high-grade components will have a higher upfront cost, the increase uptime and lower frequency of repairs will always justify the investment especially when integrated into existing manufacturing or production workflows.</li><li><strong>Scalability:</strong> If you anticipate the possibility of scaling up production or plan on working with advanced engineering materials, a sturdier quality 3D printer will be better suited to handling these demands. Opting for a lower cost alternative may seem beneficial in the short run, but longer maintenance schedules and higher downtimes may ultimately end up in requiring frequent upgrades or outright replacements of existing 3D printer units.</li></ul><h2>Impact of New Technologies</h2><p>As new features continue to be developed and integrated by manufacturers, they’re aimed at improving the reliability of 3D printers by reducing or outright eliminating the impact of user errors and optimizing long-term performance.</p><p>All of these features work towards extending the lifespan of a 3D printer and directly affect some of the factors we’ve previously outlined.</p><h3>Automated bed leveling and calibration</h3><p>Two processes that initially had a higher learning curve and required some degree of trial and error in order to ensure proper settings were achieved. Modern 3D printers use various sensors to detect and adjust the print bed’s alignment and even more advanced printers like UltiMaker’s Factor 4 has automatic calibration features for its gantry system as well.</p><h3>Automated material handling</h3><p>A newer feature in the 3D printer landscape, some printers come with either build-in or separate modules to automatically handle filament swaps and storage with some method of controlling humidity levels. Not only does this remove the need for manually swapping out filaments for longer print jobs or for prints that require multiple materials but it ensures that filaments are kept at optimal conditions reducing the associated risks that come with badly kept materials.</p><h3>Print process reporting and error detection</h3><p>While a rare feature, select advanced printers have built-in print error detection capabilities, whether done through AI monitoring via an integrated camera, sensor arrays, or various other methods, this feature is designed to ensure that parts are consistently printed to spec or in the case of more simplistic systems, it alerts the user if a print has failed and automatically stops to prevent any damage to the printer.</p><p>For example, the UltiMaker Factor 4 comes with its own dedicated <a href="https://ultimaker.com/learn/introducing-print-process-reporting/">Print Process Reporting</a>, a feature that provides detailed post-print reports that monitor and evaluate critical print parameters to ensure that each print adheres to predefined quality standards.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741155121258-Screenshot-2025-02-17-at-09.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted">Modularity</h3><p>3D printers have been modular for some time, allowing for easy upgrades and replacements. Certain components, like nozzles and extruder gears, wear out more frequently and require specific tools, along with partial disassembly and reassembly, for replacement.</p><p>True modularity has only recently started becoming a key design philosophy for professional printers where some manufacturers allow for easy replacement of assemblies with minimal or no tools.</p><p>For example Factor 4 is designed as a truly modular system where the print head, feeder module, gantry module, material station and air filter are all designed to be easily swapped out with minimal tools and expertise.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741155135661-Factor-4-1-1.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted">Software integration and ecosystems</h3><p>Probably one of the most important developments that have contributed to the improved reliability, reduced wear and tear and general future-proofing capabilities of 3D printers has been the integration within an ecosystem comprising hardware, software, materials and support services.</p><p>Two concepts guide the industry,&nbsp;<a href="https://ultimaker.com/learn/vertical-integration-vs-open-systems-what-is-it-and-why-does-it-matter/">vertical integration and open systems</a> both of which work towards ensuring that printers receive continuous firmware and software updates enabling compatibility with new features and materials as well as delivering various efficiency optimizations.</p><p>We have to note that security(both software and hardware) becomes a principal factor the importance of it increasing when considering professional workflows. Factors such as IP protection, safeguarding sensitive design files and data breach prevention become critical aspects that also play into the reliability and lifespan of a 3D printer. We’ve recently covered this subject in-depth in our Security in 3D Printing article.</p><p>UltiMaker for example has opted to combine the two in a hybrid system, with tight integration between hardware, materials, software(Cura, Digital Factory) and a comprehensive support chain, while also remaining an open system that allows users to adapt their systems using third-party materials and slicers.</p><p>The key takeaway is that the integration of 3D printers within an ecosystem has contributed a lot towards extending their lifespan and serviceability.</p><h2>UltiMaker: Built to perform, built to last</h2><p>When it comes to the lifespan of a 3D printer, reliability is key. We believe UltiMaker users should be able to depend on their tools for years to come.</p><p>UltiMaker printers have served our clients for a decade. A great example is our partner IMES3D, who still operates 23 UltiMaker 2+ printers—launched in 2016—proving their lasting performance and dependability.Our printers are designed with modularity in mind for fast and easy serviceability of components and assemblies.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741155156663-imes3d+%281%29.webp" style="width: 100%px;" class="fr-fic fr-dib"></p>

In this article we’ll take a look specifically at FDM printers and explore the factors that influence how long a 3D printer can remain functional and reliable - and what you can do to ensure that your printer stays at the top of its game for longer.

Understanding the Lifespan of a 3D Printer

<p dir="ltr" id="isPasted">In recent years, the process for developing electronics has transformed significantly due to the rise in electronic printing technologies. Compared to more conventional electronic production methods like physical vapor deposition (PVD) and etching, additive printing technologies such as direct ink writing (DIW) have ushered in a more agile and cost-effective way to design and prototype cutting-edge electronic devices, including flexible electronics and biosensors.&nbsp;</p><p dir="ltr">Not only that, advanced printing hardware, like <a href="https://www.voltera.io/nova?utm_campaign=Wevolver&utm_source=website&utm_medium=high-resolution-closed-loop-dispensing&utm_content=nova">Voltera’s NOVA materials dispensing system</a>, is unlocking unprecedented capabilities in terms of complex and highly intricate circuits, which offer enhanced functionality without significantly increasing the cost or complexity of the production process. These benefits are in large part thanks to <a href="https://www.voltera.io/blog/precision-fluid-dispensing-systems?utm_campaign=Wevolver&utm_source=website&utm_medium=high-resolution-closed-loop-dispensing&utm_content=precision-fluid-dispensing">precision fluid dispensing</a>, a system that facilitates the controlled deposition of conductive inks in micro amounts onto a substrate.</p><p dir="ltr" id="isPasted">In this article, we will explore how closed-loop precision fluid dispensing systems, such as the Smart Dispenser integrated in Voltera’s NOVA platform, are playing a central role in the development of advanced electronics and are opening up greater material possibilities for future electronic devices.</p><h2 dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/erRY7sHCaP8?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 460px;"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></h2><h2 dir="ltr">Smart Dispenser: unlocking precision with closed-loop control</h2><p dir="ltr">Voltera’s NOVA is a modular materials dispensing platform capable of printing a wide range of functional materials (conductive, dielectric, adhesives, luminescent) onto an equally diverse array of substrates, from rigid PCBs to flexible materials like PET, TPU, polymers, and paper. The system, used for the rapid development and prototyping of electronic devices, requires no tooling and minimizes material waste, resulting in 90% faster iteration times and 96% reduced material costs.</p><p dir="ltr"><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%2F1741079918299-NOVA+printing+a+stretchable+dielectric+ink.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: NOVA printing a stretchable dielectric ink.</span></span></span></p><p dir="ltr" id="isPasted">One of the key technologies behind NOVA’s versatility and precision is the Smart Dispenser, a self-contained dispensing module for ink and paste materials. In short, it is the Smart Dispenser that makes it possible to create high-resolution traces using virtually any screen printable ink (from 1,000 to 1,000,000 cps).&nbsp;</p><p dir="ltr">Depending on the viscosity of the ink used, the Smart Dispenser is able to print traces down to 100 μm in width with incredible consistency thanks to a closed-loop pressure feedback system. This system relies on an advanced pressure sensor, which monitors both the dispensing pressure and ink flow rate, as well as a new dispensing algorithm and automatic fluid level detection.&nbsp;</p><p dir="ltr">In addition to the Smart Dispenser’s closed-loop pressure feedback, the dispensing module integrates a heater, which enables users to control the temperature of the printing material. Maintaining an optimal temperature throughout the printing process is key to ensuring a stable material viscosity, which in turn results in more consistent trace widths.&nbsp;</p><p dir="ltr">Voltera has found that a temperature of 35°C (95°F) is ideal, striking a balance between keeping a stable material temperature—even with ambient temperature fluctuations and passive heating from the system’s electronics—and maintaining the ink’s properties, which could be affected by a higher temperature.[1] Other knock-on benefits of the dispenser’s heating function include minimized leakage (as a result of creating a negative pressure inside the material cartridge) and faster printing since cartridges do not need to be re-pressurized throughout the printing process. &nbsp;</p><p dir="ltr">Overall, NOVA’s Smart Dispenser and its closed-loop pressure feedback give users the ability to confidently work with a wide range of conductive inks and pastes while benefiting from rapid printing speeds and consistent print quality. From a user’s perspective, the Smart Dispenser is also adaptable, allowing for rapid material changes for multi-material prints, and can be used with various precision dispensing tips (like Nordson EFD 5CC syringe barrels and other standard Luer lock nozzles).&nbsp;</p><h2 dir="ltr" id="isPasted">Integrating the NOVA into an electronics prototyping workflow</h2><p dir="ltr">Just as users can easily swap material cartridges in the Smart Dispenser module, the entire NOVA platform is designed for ease of use. Intended for materials testing and flexible hybrid electronics R&amp;D, rapid prototyping, and small-volume production, Voltera’s NOVA dispensing platform is remarkably simple to install, enabling users to start printing shortly after unboxing and seamlessly transform their materials and electronics development workflow.</p><p dir="ltr">Setting up NOVA only takes minutes. Simply unbox NOVA’s components, connect it to power and Wi-Fi via the included USB dongle, and then log into the browser-based interface to finish the guided set-up process.[2] Additionally, NOVA can also be used in offline mode for those wanting to protect their IP.</p><p dir="ltr">Initiating the printing process is equally seamless thanks to a semi-automated calibration procedure and simple material loading with the Smart Dispenser. NOVA’s calibration process also includes test patterns, which users can check and approve remotely before the printing begins. To adjust print settings, users simply have to indicate what needs improvement (i.e. more or less pressure is needed, or changing when pressure is increased or decreased along trace starts and stops) and NOVA’s software will automatically apply the new settings. Once the user is satisfied with the calibration test, the real printing can begin. With NOVA, you only need to calibrate yourtheir materials once as it allows you to save the material profile for future use.</p><p dir="ltr">A new software feature, <a href="https://www.voltera.io/blog/print-multilayer-flexible-stretchable-circuits-nova?utm_campaign=Wevolver&utm_source=website&utm_medium=high-resolution-closed-loop-dispensing&utm_content=plan">Plan</a>, also enhances the user experience and control over output, allowing for multi-material printing of up to four stack-up layers, as well as making it possible to visualize and edit print jobs in a single workflow. Moreover, Plan offers an upgraded user experience in terms of minimizing print setup times and reducing the risk of failed prints by identifying possible errors in the planning stage.</p><p dir="ltr"><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%2F1741080015164-Multilayer+printing+using+NOVA%E2%80%99s+Plan+feature.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Multilayer printing using NOVA's Plan feature.</span></span></span></p><h2 dir="ltr" id="isPasted">Researchers leverage NOVA for GI-monitoring device</h2><p dir="ltr">Voltera’s NOVA has been eagerly adopted by a number of research labs for a range of applications, including the development of <a href="https://iopscience.iop.org/article/10.1088/2634-4386/ad63c6/meta">bioelectronics</a>, flexible <a href="https://multiplexed.mit.edu/wp-content/uploads/2023/06/transducers-2023-kachkine.pdf" data-lf-fd-inspected-kn9eq4roawkarlvp="true">displays and PCBs</a>, <a href="https://advanced.onlinelibrary.wiley.com/doi/full/10.1002/adem.202401302">materials research</a> and more. The platform’s ease of use and material versatility have also enabled researchers to explore the development of new and innovative materials for printed electronics, while advanced functions like the Smart Dispenser’s closed-loop pressure feedback and Plan software have given users access to professional, highly consistent results even at the prototyping stage. &nbsp;</p><p dir="ltr">NOVA was recently used by a research team out of the University of Southern California who were developing an ingestible electronic device to better monitor gas in the gastrointestinal (GI) tract for the diagnosis and monitoring of IBS, inflammatory bowel disease and other GI issues. NOVA was used to create wearable bend sensors to help locate the electronic pill inside the body (the pill itself is made from a PCB encapsulated in a 3D printed shell made from a biocompatible medical-grade resin). The bend sensors were made using stretchable carbon and silver inks on a PET substrate. According to the team’s research paper, published in&nbsp;Cell Reports Physical Science, NOVA offered them “high precision, reproducibility, and on-the-fly design modification capability”, all important factors when developing the non-invasive biomedical device.[3]</p><h2 dir="ltr">Transform your electronics prototyping</h2><p dir="ltr">Overall, Voltera’s NOVA platform and Smart Dispenser module give researchers and electronic product developers the means to rapidly and cost-efficiently test materials and create circuits and electronic devices with a high level of quality and consistency. This unprecedented capability opens the doors to the development of new and potentially game-changing devices, such as ingestible biosensors for health monitoring.&nbsp;</p><h3 dir="ltr">References</h3><p dir="ltr">[1] Why do we heat the Smart Dispenser? [Internet]. Voltera, 2024. <a href="https://docs.voltera.io/nova/learn-more/why-do-we-heat-the-smart-dispenser">https://docs.voltera.io/nova/learn-more/why-do-we-heat-the-smart-dispenser</a>&nbsp;</p><p dir="ltr">[2] Voltera. Voltera NOVA: Unboxing and First Time Setup [Internet]. Youtube, August 17, 2023. <a href="https://www.youtube.com/watch?v=dcAq5-zZj_Y">https://www.youtube.com/watch?v=dcAq5-zZj_Y</a>&nbsp;</p><p dir="ltr">[3] Abdigazy A, Arfan M, Shao J, Islam MS, Hassan MF, Khan Y. 3D gas mapping in the gut with AI-enabled ingestible and wearable electronics. Cell Reports Physical Science. 2024 Jul 17;5(7).</p>

Precision nozzle on NOVA’s Smart Dispenser

Discover how NOVA’s Smart Dispenser module unlocks consistent and high-precision trace printing for a range of ink viscosities.

High-Resolution Electronics Prototyping: Pushing the Limits with Closed-Loop Dispensing Systems

<h2 id="isPasted">How additive printing is changing the face of customized products</h2><p>Additive printing, commonly known as 3D printing, has rapidly emerged as one of the most transformative technologies in manufacturing. By allowing manufacturers to build objects layer by layer, this technique has revolutionized the way products are designed, produced, and customized. The capability of additive printing to offer mass customization at scale has redefined traditional manufacturing methods, making it possible to create individualized products that cater to the specific needs and preferences of consumers.</p><h2><strong>Introduction to Additive Printing and Customized Production</strong></h2><p>Additive printing has come a long way since its inception in the 1980s. Initially, it was used primarily for rapid prototyping, but as the technology advanced, it evolved into a full-fledged manufacturing solution. Unlike traditional manufacturing, which relies on subtractive processes (such as cutting or milling), additive printing constructs products layer by layer, using digital models. This process allows for greater flexibility in design and significantly reduces waste. Barring a short period in the early 2010s, 3D printing hasn’t been deeply popular with general consumers. That said, the market for commercial 3D printing is now booming.</p><p>One of the most profound impacts of additive printing is its ability to enable mass customization. Traditional manufacturing methods require expensive molds and tooling, making customization costly and time-consuming. Additive printing, on the other hand, allows for cost-effective production of small batches or even single customized items, eliminating the need for specialized tools. This makes it possible to create tailored products, from&nbsp;<a href="https://xtpl.com/healthtech/">healthcare devices</a> to fashion accessories, at a fraction of the cost and time required by traditional methods.</p><h3><strong>Key Technologies Behind Additive Printing</strong></h3><p>Several key technologies drive the additive printing revolution. Each has its own strengths, depending on the materials, precision, and applications involved. Some of the most commonly used additive printing technologies include:</p><ul><li><strong>Fused Deposition Modeling (FDM)</strong>: FDM is one of the most widely used 3D printing techniques. It works by melting a thermoplastic filament and depositing it layer by layer. FDM is popular for its affordability and ability to print with a wide range of materials, making it suitable for prototyping and creating custom consumer goods.</li><li><strong>Stereolithography (SLA)</strong>: SLA uses a laser to cure liquid resin into solid layers. This method is known for its high precision and smooth surface finish, making it ideal for applications that require fine details, such as dental and medical devices.</li><li><strong>Selective Laser Sintering (SLS)</strong>: SLS uses a laser to fuse powdered material layer by layer. It allows for greater material flexibility and can produce more complex designs than FDM. SLS is commonly used in industrial applications where material strength and durability are crucial.</li></ul><p>These technologies have become increasingly accessible and versatile, allowing for a wide range of applications in different industries. Additionally, the use of digital design and modeling software enhances the potential for customization, enabling designers to create highly detailed and unique products tailored to individual needs.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740973743234-xtpl_story_concept_03.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>Revolutionizing Product Customization with Additive Printing</strong></h2><p>Additive printing has revolutionized product customization in several industries, enabling the creation of products that were previously difficult or impossible to manufacture using traditional methods. Some of the most impactful applications include:</p><ul><li><strong>Healthcare</strong>: Additive printing has made significant strides in healthcare, particularly in the production of&nbsp;<a href="https://xtpl.com/nanotechnology-in-healthtech-biofunctional-coatings-for-implantable-devices/">customized prosthetics and implants</a>. By scanning a patient’s body, doctors can create custom-fitted prosthetics that offer greater comfort and functionality. In addition, 3D-printed dental aligners and hearing aids are now widely available, providing patients with tailored solutions.</li><li><strong>Fashion</strong>: In the fashion industry, additive printing has enabled the creation of wearable technology and custom-fit accessories. Designers can now create intricate, personalized pieces, from jewelry to shoes, that fit individual preferences and measurements. This has opened new opportunities for designers to experiment with unique forms and materials that were not feasible with conventional manufacturing methods.</li><li><strong>Consumer Goods</strong>: Custom-fit earphones, eyewear, and other consumer goods are now commonly produced using additive printing. By allowing for precise customization, manufacturers can cater to the specific needs of consumers, offering better comfort, performance, and aesthetics.</li></ul><p>Additive printing offers several key benefits for customization, including reduced waste, shorter production cycles, and the ability to produce complex designs that are unachievable with traditional methods. However, there are still challenges, such as material limitations, quality control, and cost efficiency, that manufacturers must overcome to fully capitalize on the potential of additive printing for mass customization.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740973755337-xtpl_story_concept_11B.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">The Impact of Additive Printing on Supply Chains and Retail</h2><p>The rise of additive printing has the potential to reshape supply chains and retail models. Traditionally, manufacturers have had to produce large quantities of products in advance, leading to excess inventory, storage costs, and the risk of unsold goods. Additive printing offers a solution to these issues by enabling on-demand production. This means that products can be printed as needed, eliminating the need for large inventories and reducing lead times.</p><p>In addition, additive printing allows for more localized production. Instead of relying on centralized factories, companies can establish smaller, decentralized manufacturing hubs closer to consumers, reducing shipping times and costs. This shift towards a made-to-order approach could significantly alter traditional retail models, allowing consumers to order customized products directly from manufacturers or even print products at home using personal 3D printers.</p><p>However, integrating additive printing into existing production and distribution systems will require careful planning. Companies must consider how to maintain quality control, ensure cost efficiency, and manage the complexities of producing a wide range of customized products.</p><h3><strong>Future Trends and Developments in Additive Printing for Customization</strong></h3><p>The future of additive printing for customization is bright, with emerging materials and technologies set to enhance its capabilities further. Researchers are developing new materials, such as bio-based polymers and advanced metals, which will expand the range of products that can be customized through additive printing. These materials will offer improved performance, durability, and environmental sustainability.</p><p>AI and machine learning are also poised to play a key role in optimizing the additive printing process. By analyzing data from previous prints, AI can help optimize designs, reduce errors, and improve production efficiency. Machine learning algorithms can also assist in predicting material behavior, further improving the quality and consistency of customized products.</p><p>Looking ahead, the widespread adoption of additive printing for customization could have far-reaching implications. It may lead to more sustainable manufacturing practices, as products will be printed on demand, reducing waste and excess inventory. Additionally, consumers may increasingly expect personalized products, leading to changes in consumer behavior and new business models focused on customization.</p><p>Additive printing is transforming the way products are designed, manufactured, and customized. By offering unparalleled flexibility, precision, and cost-efficiency, it is enabling unprecedented levels of product customization across a wide range of industries. As additive printing technologies continue to evolve, they will play an even greater role in shaping the future of manufacturing and consumer experiences.</p>

Additive printing, commonly known as 3D printing, has rapidly emerged as one of the most transformative technologies in manufacturing. By allowing manufacturers to build objects layer by layer, this technique has revolutionized the way products are designed, produced, and customized.

How additive printing is changing the face of customized products

<div data-layout="content" id="isPasted"><p>Fused Deposition Modeling (FDM) and Fused Filament Fabrication (FFF) are cornerstone technologies in additive manufacturing.</p><p>Both FDM &amp; FFF create three-dimensional objects by extruding melted thermoplastic filament through a nozzle, building up layers to form the final product. The distinction between FDM and FFF lies not in the technology itself, but in their origins.</p><p>Stratasys developed and trademarked FDM in 1989 as their proprietary process. The RepRap project later coined FFF in 2005 as a generic term describing the same method, allowing its use by any manufacturer. FDM and FFF printers share common components: an extruder for heating and depositing filament, a build platform, motors for movement, and a filament feeding system.</p><p>The printing process for both technologies involves heating thermoplastic to its melting point, extruding it through a nozzle, and depositing material layer by layer based on a 3D model. As each layer cools, it bonds to the one below. Common materials include PLA, ABS, and PETG, along with specialty filaments. This approach to 3D printing is valued for its accessibility, cost-effectiveness, and ability to produce functional prototypes and parts across diverse industries. To maximize your success with FDM/FFF printing, it's essential to&nbsp;<a href="https://ultimaker.com/learn/design-for-fff-3d-printing-maximize-your-success/">understand design best practices for this technology</a>.</p></div><div data-layout="content"><h2>FDM meaning: Fused deposition modeling explained</h2><p>Fused deposition modeling (FDM) is an additive manufacturing technique that builds three-dimensional objects by depositing melted thermoplastic in precise layers. Stratasys coined the term "FDM" when they developed and patented this method in 1989.</p><p>FDM technology centers on extruding heated material through a nozzle, constructing objects layer by layer, using thermoplastic filaments, and controlling the deposition process via computer. An FDM 3D printer typically consists of an extruder for heating and depositing filament, a build platform, motors for movement, and a filament feeding mechanism.</p><p>The printing process begins by heating thermoplastic filament to its melting point. The printer then extrudes this molten plastic through a nozzle, depositing it in layers according to the 3D model. Each layer cools and bonds to the previous one, gradually forming the complete object. FDM's strengths lie in its affordability, wide material compatibility, and ability to create functional prototypes and end-use parts. It finds applications in automotive, aerospace, and consumer goods industries.</p><p>While Stratasys trademarked "FDM," the same technology is known as Fused Filament Fabrication (FFF) when used by other manufacturers. In practice, these terms are often used interchangeably in the 3D printing field.</p></div><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740642340904-FDM-vs-FDA2.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">FFF acronym meaning: Fused filament fabrication defined</h2><p>Fused filament fabrication (FFF ) is a 3D printing method that creates objects by depositing melted thermoplastic in precise layers.</p><p><strong>The RepRap project introduced the term "FFF" in 2005 as a non-trademarked alternative to "Fused Deposition Modeling" (FDM).</strong></p><p>Identically to FDM, FFF technology involves extruding melted thermoplastic through a heated nozzle, building objects layer by layer under computer control, using various thermoplastic materials as printing filament.</p><p>For those looking to explore FFF technology, desktop 3D printers like the <a href="https://ultimaker.com/3d-printers/sketch-series/makerbot-sketch-sprint/">Sketch Sprint</a> or <a href="https://ultimaker.com/3d-printers/s-series/ultimaker-s3/">UltiMaker 3&nbsp;</a>offers an excellent entry point for both beginners and professionals.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740642348249-FDM-vs-FFF.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">Comparing FDM and FFF to other 3D printing technologies</h2><p>FDM and FFF differ significantly from other additive manufacturing technologies like SLA (stereolithography) and SLS (selective laser sintering). Comparing FDM/FFF to SLA reveals differences in materials (thermoplastic filaments vs. liquid photopolymer resins), printing process (extrusion of melted plastic vs. curing resin with UV light), resolution (SLA typically achieves higher resolution and smoother surfaces), and applications (FDM/FFF suits functional prototypes, while SLA excels in detailed models and jewelry).</p><p>When comparing FDM/FFF to SLS, notable differences include materials (filaments vs. powdered materials, usually nylon), printing process (depositing material layer-by-layer vs. sintering powder with a laser), strength (SLS parts often exhibit greater strength and suitability for functional components), and complexity (SLS can produce more intricate geometries without support structures).</p><p>FDM/FFF technologies offer advantages such as lower entry costs for both printers and materials, a wider range of thermoplastic options, easier material changes and multi-material printing, and simpler post-processing. However, limitations include lower resolution and less smooth surface finish, visible layer lines, anisotropic strength (weaker in the Z-axis), and limited ability to produce complex internal structures.</p><p>When selecting between FDM/FFF and other technologies, consider factors like required resolution, material properties, cost, and intended application to determine the best fit for your specific needs. For those looking to explore the capabilities of FDM/FFF technology,&nbsp;<a href="https://ultimaker.com/">UltiMaker offers a range of professional 3D printing solutions</a> suitable for various applications and industries.</p>

Both FDM & FFF create three-dimensional objects by extruding melted thermoplastic filament through a nozzle, building up layers to form the final product. The distinction between FDM and FFF lies not in the technology itself, but in their origins.

FDM vs FFF: Understanding 3D Printing Technologies

<div data-layout="content" id="isPasted"><p>3D printing has now become commonplace to the point where it has expanded beyond its own initial hobby space.</p><p>While it took a bit longer for industrial 3D printing to permeate the various manufacturing landscapes, it is now seeing more and more use in various applications across different industries such as defense, packaging, and automotive.</p><p>Let's dive into the many use cases and applications 3D printing has introduced since its inception, explore where it might be headed, and see how&nbsp;<a href="https://ultimaker.com/">UltiMaker</a> fits into this evolving timeline of past, present, and future.</p><h2>The early years of 3D printing</h2><p>Dr. Hideo Kodama of the Nagoya Municipal Industrial Research Institute in Japan is often credited as the pioneer of 3D printing technology. In 1981, he published a paper demonstrating how photopolymers could be used to create solid 3D objects layer by layer, with each layer representing a cross-sectional slice of the intended design.</p><p>Although his concept wasn’t immediately applied in practice, Charles “Chuck” Hull later patented the stereolithography apparatus (SLA) and founded 3D Systems Corporation, which went on to release the first commercial 3D printer, the SLA-1.</p><h3>The first applications in 3D printing - prototyping</h3><p>SLA-1 vastly improved the prototyping capabilities in the automotive industry at the time as traditional injection molding for plastic part creation required a one-off tooling process that took 6 to 8 weeks which would further need to be refined in subsequent iterations that stretched mold making into a multiple-month process.</p><p>Two years later in 1988, we saw the advent of two more 3d printing technologies:</p><ul><li>Scott Crump (co-founder of Stratasys) developed the Fused Deposition Modeling (FDM) process, in which 3d prints objects by extruding thermoplastic material layer by layer.</li><li>Carl Deckard patented the Selective Laser Sintering process which 3d prints objects by sintering(melting) fine polymer powder particles to fuse them locally.</li></ul><p>By the end of 1988, we had the 3 main technologies of 3D printing still in use today: SLA, FDM and SLS. However so far the applications were limited to manufacturing companies as at the time they carried a hefty price tag of around $300.000 with one of the more affordable models being the 3D Modeler that Stratasys sold for around $130.000.</p></div><div data-layout="content"><h2>Age of innovation</h2><p>The 90’s saw the first instances of 3D printing technologies challenging the traditional subtractive manufacturing methods such as casting, CNC milling and stamping, especially with the emergence of new CAD tools that allowed the creation of complex 3d models. Bioprinting was also gaining traction in the medical field and the entire additive manufacturing scene was on the verge of a new paradigm shift.</p><h3>First medical application</h3><p>While another 3D printing technology emerged in 1997 developed by AeroMat which used high-powered lasers to fuse powdered titanium alloys(LAM - Laser Additive Manufacturing), the Wake Forest Institute of Regenerative Medicine was the first to 3D bioprint an organ(bladder) and also successfully transplant it in a human.</p></div><div data-layout="content"><h2>Road to affordability</h2><p>2005 saw the beginning of the RepRap project, initiated by Dr. Adrian Bowyer at the University of Bath which was the first open-source initiative that aimed to create a self-replicating 3D printer. This aimed to make the technology more accessible and affordable as all other 3D printing solutions available at the time were still proprietary.</p><p>Shortly after, in 2006 Fab@Home, led by students at Cornell University’s Department of Mechanical &amp; Aerospace Engineering, joined RepRap in sparking the consumer 3D printing revolution with their Fab@Home Model 1 printer which was replicated and saw hundreds of units built across the world. Important to note that some of the design elements would later be found in later DIY printers, notably the first MakerBot Replicator in 2009.</p><p>Speaking of MakerBot, we have to mark 2008 as the year Thingiverse was launched by Zach Smith (a co-founder of MakerBot) which became the most widely known and largest repositories of open-source 3D models catering to hobbyists, educators, and professionals alike.</p><p>In 2009 the patent held by Stratasys for FDM expired, which caused the average FDM 3D printer price to drop from ~$10.000 to ~$1000 paving the way for affordable 3D printing for the wider crowd.</p></div><div data-layout="content"><h2>Widespread use</h2><p>By 2011 printers had already seen a surge in the range of applications being used with the market now steadily expanding into the DIY hobbyist space the stage was set for widespread adoption. This year marked the first instance of a 3D printed unmanned aircraft made by the engineers at the University of Southampton showcasing the technology’s capabilities in aerospace applications, similarly, Urbee, the first 3D printed car was unveiled by Fabbaloo in Winnipeg.</p><p>Applications ranged from experimental confectionery with researchers at the University of Exeter developing a 3D printer capable of printing with chocolate to the first successful zero-gravity tests being completed by 3D Systems in partnership with Made in Space to demonstrate the feasibility of 3D printing in space environments.</p><p>We also have to note that this year marked the release of the first UltiMaker printer, the UltiMaker Original, a DIY kit featuring laser-cut wood components that allowed users to assemble and customize their 3D printer.</p><p>On the same note, the Cura slicer software was also first released in 2011, developed by David Braam it was initially intended to support Ultimaker’s 3D printers but over time evolved into one of the most widely used open-source slicers compatible with a variety of 3D printers.</p></div><div data-layout="content"><h2>Out-of-the-box ready</h2><p>In September 2013 the UltiMaker 2 was introduced as the company’s first out-of-the-box 3D printer, requiring minimal setup and single extrusion capabilities, it was targeted at home-users, schools, libraries, small businesses as well as industrial designers who wanted to leverage 3d printing for rapid prototyping and production.</p><p>The inclusion of a heated bed in the design also allowed it to print a wider range of materials like the relatively recently introduced PETG (late 2010s), Nylon, TPU and more.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740129241820-UtltiMaker-2.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><div data-layout="content" id="isPasted"><p>This marked a pivotal change in the 3D printing landscape as the quality and precision offered were unmatched in the price range (~$2500 at launch) coupled UltiMaker’s commitment to open-source development, this appealed to a large community and fostered innovation and cemented the large scale adoption of 3D printers around the world.</p><p>In 2012 the distribution of DIY and consumer printers outpaced the sales of industrial printers for the first time marking the end of the Fab@Home project.</p></div><div data-layout="content"><h2>Industrial renaissance</h2><p>We’ve almost come full circle as the 3D printing scene started to loop back into the industrial application space. Due to the affordability and expanding range of materials available for 3D printing, the technology started seeing widespread use in various industrial applications beyond the prototyping core use case it was already used to.</p><h3>A fashionable choice</h3><p>The apparel industry has seen its first uses of 3D printing with fashion designers experimenting with various clothing articles and in commercial production Nike started using 3D printing to prototype and manufacture the 2012 Vapor Laser Talon football shoe for players of American football.</p><p>Even high fashion courtiers that designed for famous brands like Chanel worked with technology from Stratasys to employ 3D printing in their collections.</p><p>Handbag and jewelry manufacturing also saw successful and widespread adoption of 3D printing technology to create molds or even jewelry itself with its innate ability to quickly create customized models gaining favor among professionals in the industry.</p><p>For example, <a href="https://ultimaker.com/learn/producing-customized-fashion-solutions-with-ultimaker-3d-printers/">Florenradica</a>, a design company based near Florence, Italy, fabricated prototypes and end-use parts for fashion houses.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740129259179-fashion.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">Construction and Transportation</h2><p>The construction industry saw the first 3D-printed two-story house built in 45 days by Chinese company HuaShan Tengda in 2014. This marked the start of an exploration of 3D printing as a cost-effective construction method with Apis Cor 3D managing to print the structure of a 400-square-foot house in only 24 hours.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740129274126-3D-Printer-Concrete-1.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">2015 saw Local Motors, an automotive manufacturing company, develop the LM3D Swim, a vehicle that was 80% 3D printed and Airbus announced that their Airbus A350 XWB included over 1000 3D printed components.</p><p>In the same year, a Royal Air Force Eurofighter Typhoon fighter jet flew with printed parts.</p><h2>Picking up the pace with UltiMaker</h2><p>The UltiMaker 2+ 3D printer was launched in 2016 featuring an improved feeder system, interchangeable nozzles, and enhanced cooling for better print quality.</p><p>By now, some industry leaders like Siemens were&nbsp;<a href="https://ultimaker.com/learn/using-ultimaker-3d-printers-for-manufacturing-at-siemens/">already using UltiMaker printers in their manufacturing lines</a> to reduce lead times on creating part molds and save up on costs.</p><p>Similar success stories with the UltiMaker 2+ printers see them being used to create <a href="https://ultimaker.com/learn/saving-eyesight-with-a-3d-printed-eye-examination-kit/">smartphone retinal imaging adapters</a> to help doctors diagnose eyesight problems or help with surgical planning by using <a href="https://ultimaker.com/learn/surgical-planning-using-3d-printed-bone-models/">3D printed bone models</a>.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740129306648-1740129306648.png" class="fr-fic fr-dib"></p><p id="isPasted">Along with the UltiMaker 2+ the same year marked the debut of the new UltiMaker 3 which introduced dual extrusion capabilities and was compatible with more materials like PVA, PC, ABS and others.</p><p>One of the companies that took advantage of the expanded range of materials was&nbsp;<a href="https://ultimaker.com/learn/volkswagen-autoeuropa-maximizing-production-efficiency-with-3d-printed-tools-jigs-and-fixtures/">Volkswagen Autoeuropa&nbsp;</a>who switched to 3D printing as the main solution for creating custom tooling, jigs and fixtures for their car production lines.</p><p>2018 was turning point for UltiMaker as it partnered with material manufacturers DSM, BASF, DuPont Transportation &amp; Advanced Polymers, Owens Corning, Mitsubishi, Henkel, Kuraray, Solvay, and Clariant to create new material profiles for printing high-level engineering plastics and composites.</p><p>This along with the launch of the brand new S series of printers debuting with the UltiMaker S5 developed for the professional market cemented the company’s new focus on the industrial sector and away from the hobbyist market.</p><p>We also have to note that 2018 marked the year that 3D printing became an everyday accessibility with low cost printers(~$200 price range) aimed at novice users, brought a renewed wave of interest into the 3D printing space.</p><p>Applications continued to evolve and in 2021 a British patient received the world’s first fully 3D-printed prosthetic eye, indicating advancements in personalized medical prosthetics, while in the same year advancements in construction saw Luyten 3D build the first code-compliant 3D-printed home in Melbourne, Australia.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740129324876-Evolution-of-3D-printing-.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">In 2022 UltiMaker and MakerBot merged and leveraged the strengths of both brands to advance the adoption of additive manufacturing globally by providing a wider range of solutions from desktop 3D printers for education to professional-grade tools for businesses.</p><p>Building up on the success of the previous year, the UltiMaker S7, UltiMaker Method XL, and MakerBot Sketch were released in 2023 alongside new developments to Cura which now included settings for interlocking structure generation for dual extrusion as well as new high-performance composite materials like the easy-to-use PET CF.</p><p>By the end of <strong>2024</strong> UltiMaker’s solutions were utilized by customers like the <a href="https://ultimaker.com/learn/on-demand-spare-parts-the-royal-netherlands-navys-3d-printing-solution/">Royal Netherlands Navy</a>, <a href="https://ultimaker.com/learn/audi-sport-3d-printed-tools-jigs-and-fixtures-in-a-day-instead-of-weeks/">Audi</a>, <a href="https://ultimaker.com/learn/krones-optimized-3d-printed-parts-spares-for-customers-anywhere/">Krones</a>, hinting that the increased adoption of additive manufacturing technologies might be the way forward for a more sustainable, cost-efficient, better future.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740129341990-Still-2024-11-06-092512_3.1.24-1.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">Where to now?</h2><p>So what are the next steps for 3D printing? In 2016 EY published their Global 3D Printing Report that assertively stated that 3D printing will become a game changer and described how 3D printing can become part of production in 3 ways: adopted as an additional technology in the existing production process, combined with traditional technologies in a form of hybrid technology or as a replacement for traditional methods.</p><p>And it looks like they were right, as regardless of the industry vertical we’re looking at, whether it’s manufacturing, packaging and automation, transportation, medical or defense, the ability to rapidly prototype and iterate parts, manufacture tooling and fixtures, create spare parts and more, are becoming deciding factors on whether businesses can remain competitive.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740129360632-Krones-video-cover-B-3.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p>We firmly believe that 3D printing technologies will become an integral part of the future, both in education(for which we’ll reserve a separate article) and professional business sectors. The advantages are clear and we’ve specifically talked about the benefits of 3D printing in the past, such as in the&nbsp;<a href="https://ultimaker.com/learn/benefits-of-3d-printing-in-automated-packaging/" id="isPasted">automated packaging industry,</a> <a href="https://ultimaker.com/learn/benefits-of-3d-printing-in-manufacturing/">manufacturing industry</a> and we’re excited to see new applications come forth as adoption continues to grow.</p></div></div>

Let's dive into the many use cases and applications 3D printing has introduced since its inception, explore where it might be headed, and see how UltiMaker fits into this evolving timeline of past, present, and future.

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