Articles tagged with "3D-printing"
US lab plans dual-material 3D printing to boost aircraft, energy tech
Oak Ridge National Laboratory (ORNL), in partnership with JuggerBot 3D, is developing a novel dual-material 3D printing system capable of processing both thermoplastic and thermoset polymers in a single manufacturing process. This hybrid approach aims to combine the flexibility and ease of thermoplastics with the superior thermal and chemical resistance of thermosets, enabling the production of complex parts with varied material properties. The project builds on prior work that improved large-format thermoplastic printing by refining ORNL’s open-source slicing software and integrating a laser-based real-time calibration system, which enhanced print consistency and reduced the need for post-processing. A significant advancement from the initial collaboration was the automation of material setup through a “Material Card” database, which stores process parameters for different materials. This innovation, paired with ORNL’s Slicer 2 software and calibration technology, streamlines operations by eliminating the need for repeated calibration when switching materials, saving considerable time. The current focus is on adapting this framework to
3D-printingadditive-manufacturingdual-material-printingthermoplasticsthermosetsenergy-technologyOak-Ridge-National-LaboratoryScientists develop algae-based concrete that captures 142% more carbon
Researchers at the University of Pennsylvania have developed an innovative algae-based concrete that significantly reduces environmental impact while maintaining structural integrity. By incorporating diatomaceous earth—powder made from fossilized silica shells of microscopic algae—into a 3D-printed concrete mix, the team created a lightweight material that uses 68% less cement and absorbs 142% more CO₂ compared to traditional concrete. This breakthrough leverages the natural carbon-trapping abilities of diatoms and a mathematically optimized internal geometry inspired by coral reefs and sea stars, known as triply periodic minimal surfaces (TPMS), which maximize surface area and stiffness with minimal material. The new concrete not only captures more carbon dioxide but also grows stronger over time during curing, retaining 90% of the strength of conventional solid concrete blocks despite its high porosity. The design incorporates post-tensioning cables and advanced force-balancing geometries to ensure durability and buildability at architectural scales. The researchers are currently scaling up the technology for larger applications such
materialsconcretecarbon-capturesustainable-construction3D-printingdiatomaceous-earthcarbon-dioxide-absorptionQatar turns desert sand into the world’s largest 3D printed structure
Qatar has embarked on constructing the world’s largest 3D-printed buildings—two public schools each covering 20,000 square meters—using massive custom-built printers from Denmark’s COBOD. This project, part of a larger plan to build 14 schools totaling 40,000 square meters, represents a 40-fold increase in scale compared to the previous largest 3D-printed structure, a 10,000-square-foot equestrian facility in Florida. The printers, each the size of a Boeing 737 hangar, extrude specialized concrete layer by layer to create walls with flowing, dune-like curves inspired by Qatar’s desert landscape. Over the past eight months, a multidisciplinary team in Doha has conducted more than 100 full-scale test prints, optimizing concrete mixes and printer technology to withstand Qatar’s harsh climate. Printing primarily occurs at night to enhance material performance and reduce environmental impacts such as dust, noise, and energy use. The project not only pushes the boundaries of large-scale additive
3D-printingconstruction-technologymaterials-scienceadditive-manufacturingconcrete-innovationdigital-constructioninfrastructure-developmentMan’s deadly chest ‘time bomb’ removed using 3D-printed aorta model
Surgeons at Brisbane’s Prince Charles Hospital successfully performed a rare and complex operation to replace nearly the entire aorta of a man in his late 50s, whose vessel had ballooned to about four times its normal size, posing an imminent risk of fatal rupture. The life-threatening condition, described as a “ticking time bomb,” was discovered during routine monitoring. To prepare for the intricate nine-hour surgery, the team collaborated with the Herston Biofabrication Institute to create a life-sized, multi-material 3D-printed model of the patient’s distorted aorta. This tactile model, produced from detailed CT scans, allowed surgeons to rehearse the procedure more effectively than traditional two-dimensional imaging. During surgery, the patient’s body was cooled and circulation temporarily stopped to enable safe removal of the diseased aortic arch, which had expanded to about eight centimeters—far beyond the normal two to three centimeters. The damaged section was replaced with a synthetic graft resembling “flexible, waterproof jackets.”
3D-printingsynthetic-graftmedical-materialsbiofabricationvascular-surgerymulti-material-printingmedical-technology3D-printed jet engine hits 13,000 feet in China’s maiden flight test
China has successfully conducted the maiden flight test of its first fully 3D-printed mini turbojet engine, which reached an altitude of 13,000 feet (4,000 meters) in the Inner Mongolia Autonomous Region. This 160-kilogram thrust-class engine was produced using a combination of additive manufacturing and multi-disciplinary topology optimization, allowing for complex, lightweight, and integrated components that traditional casting and forging methods cannot easily achieve. The development represents a significant technical milestone for China’s aerospace sector, potentially reducing its reliance on foreign-sourced engines and addressing longstanding challenges in metallurgy and precision engineering. While additive manufacturing is already established in the aerospace industry globally—with companies like GE Aviation and Pratt & Whitney using 3D-printed parts—China’s achievement lies in producing an entire flight-validated engine through these methods. The lightweight engine is expected to be particularly useful for unmanned aerial vehicles (UAVs). However, transitioning from a prototype to industrial-scale production poses challenges, including advancements in high-temperature
3D-printingadditive-manufacturingaerospace-materialsjet-engine-technologyadvanced-manufacturingmaterials-engineeringaerospace-innovationMIT student’s pocket-sized 3D printer can craft objects in seconds
Researchers at MIT, led by PhD candidate Sabrina Corsetti and Professor Jelena Notaros, have developed a groundbreaking pocket-sized 3D printer based on a single millimeter-scale photonic chip. This chip uses light to create solid objects within seconds by emitting reconfigurable visible-light holograms into a stationary resin well, enabling non-mechanical 3D printing without any moving parts. The innovation combines silicon photonics and photochemistry to achieve rapid fabrication of customized, low-cost objects, marking the first demonstration of chip-based 3D printing. This compact and portable system addresses many limitations of traditional 3D printers, which rely on large mechanical setups that restrict speed, resolution, and form factor. Beyond 3D printing, the team also created a miniature “tractor beam” using light to manipulate biological particles, offering new possibilities for contamination-free biological research. The researchers anticipate that their chip-based technology could revolutionize manufacturing across diverse fields such as military, medical, engineering, and consumer applications
materials3D-printingphotonicssilicon-photonicsphotochemistryoptical-tweezersmanufacturing-technology‘Shocking’ 3D resin may build soft robots with plastic-like strength
Researchers at the University of Texas at Austin have developed an innovative 3D printing technique that uses a custom liquid resin and a dual-light system to create objects combining both soft, rubber-like flexibility and hard, plastic-like strength within a single print. Inspired by natural structures such as human bones and cartilage, this method employs violet light to produce flexible material and ultraviolet light to harden the resin, enabling seamless transitions between soft and rigid zones without weak interfaces. This breakthrough addresses common issues in multi-material printing where different materials often fail at their boundaries. Demonstrations of the technology included printing a functional knee joint with soft ligaments and hard bones that moved smoothly together, as well as a stretchable electronic device with flexible and stiff areas to protect circuitry. The researchers were surprised by the immediate success and the stark contrast in mechanical properties achieved. An adjacent study published in ACS Central Science further highlights the potential of light-driven resin chemistry to advance additive manufacturing, offering faster production, higher resolution, and new design freedoms.
3D-printingsoft-roboticsadvanced-materialsresin-technologyflexible-electronicsdual-light-curingmaterial-scienceMIT's new AI outsmarts human design to help robots jump 41% higher
MIT’s Computer Science and Artificial Intelligence Laboratory (CSAIL) has developed a new generative AI approach that designs robots capable of jumping 41% higher than those created by human engineers. Using diffusion-based generative models, researchers allowed the AI to modify specific parts of a 3D robot model, resulting in curved linkages resembling thick drumsticks rather than the straight, rectangular parts of traditional designs. This unique shape enabled the robot to store more energy before jumping, improving performance without compromising structural integrity. The AI-assisted robot also demonstrated an 84% reduction in falls compared to the baseline model, highlighting enhanced stability and landing safety. The process involved iterative refinement, with the AI generating multiple design drafts that were scaled and fabricated using 3D-printable polylactic acid material. Researchers believe that future iterations using lighter materials could achieve even higher jumps. Beyond jumping robots, the team envisions applying diffusion models to optimize how parts connect and to design robots with more complex capabilities, such as directional control and
roboticsartificial-intelligencegenerative-AIrobot-design3D-printingmaterials-sciencerobotics-innovationUS: World’s most advanced rocket engine tested for hypersonic drones
The US startup New Frontier Aerospace (NFA) has successfully completed critical fire tests of its Mjölnir rocket engine, a cutting-edge propulsion system designed for next-generation hypersonic drones and space vehicles. Unlike most aerospace engines that use RP-1 or liquid hydrogen, Mjölnir runs on liquid natural gas (LNG), which is a cleaner-burning fuel and can become net carbon-negative when sourced from bio-waste. The engine features a full-flow staged combustion cycle—an advanced architecture that improves efficiency, thrust-to-weight ratio, and engine longevity—and is 3D-printed to reduce manufacturing costs and enable rapid development. Supported by NASA and the Defense Innovation Unit, Mjölnir demonstrated stable ignition, precise throttle control, and consistent thermal performance, confirming its reliability as a main propulsion system. Mjölnir is set to power two key NFA platforms: Pathfinder, a hypersonic vertical takeoff and landing (VTOL) unmanned aerial system aimed at rapid military
energyrocket-enginehypersonic-dronesliquid-natural-gasaerospace-propulsion3D-printingsustainable-fuelSynthetic lichen could 3D print homes on Mars using Martian soil
Researchers led by Dr. Congrui Grace Jin at Texas A&M University have developed a synthetic lichen system that could autonomously create building materials on Mars using only Martian soil simulant, air, light, and an inorganic liquid medium. This bio-manufacturing approach mimics natural lichens, which are symbiotic communities of fungi and cyanobacteria. The cyanobacteria fix carbon dioxide and nitrogen from the Martian atmosphere, producing oxygen and nutrients, while the fungi bind metal ions and help form biominerals. Together, they secrete biopolymers that glue Martian regolith particles into solid structures, enabling the creation of building materials without human intervention or external nutrient supplies. This innovation addresses major challenges in extraterrestrial construction by eliminating the need to transport heavy materials from Earth or rely on continuous human assistance. Funded by NASA’s Innovative Advanced Concepts program, the technology promises to facilitate autonomous 3D printing of habitats, furniture, and other structures on Mars. The team is currently
materials3D-printingsynthetic-lichenMartian-soilbio-manufacturingspace-constructionbiomaterialsRevolutionary 3D magnet setup could slash MRI costs and boost access
German physicists from the University of Bayreuth and Johannes Gutenberg University Mainz have developed a novel magnetic field design that surpasses the traditional Halbach array by delivering stronger, cheaper, and more uniform magnetic fields in a compact setup. Their innovation involves arranging 16 tiny neodymium (FeNdB) magnet cuboids in optimized three-dimensional orientations on 3D-printed supports, forming single or stacked double rings. This focused design maintains magnetic field strength and uniformity not only within the magnet plane but also above it, addressing a key limitation of the Halbach array, which struggles to produce uniform fields in finite-sized, practical applications. This breakthrough holds significant promise for technologies requiring stable, homogeneous magnetic fields, particularly medical imaging. Conventional MRI machines rely on costly, complex superconducting magnets that require cryogenic cooling, limiting access in rural and underserved regions. The new permanent magnet configuration offers a low-cost, energy-efficient alternative that could make MRI technology more accessible in remote clinics, mobile health units, and
materialsmagnet-design3D-printingneodymium-magnetsMRI-technologymagnetic-fieldsmedical-imagingScientists 3D-print thermal insulation fibres from wheat straw
Researchers led by Dr. Chi Zhou at the University at Buffalo have developed a sustainable thermal insulation material by 3D-printing fibers derived from wheat straw, an agricultural byproduct typically burned after harvest. Wheat straw’s natural fibrous and porous structure provides effective thermal insulation, high mechanical strength, and enhanced flame retardancy compared to other organic materials. The process involves pulping wheat straw into a slurry, drying it into a thick ink, and cross-linking the fibers with an organic binder to ensure material integrity before 3D printing. This innovation offers a renewable, biodegradable alternative to conventional insulation materials like glass and rock wool, which rely heavily on fossil fuels and contribute to greenhouse gas emissions. To address the slow printing speed of early methods, Zhou’s team redesigned the 3D printer with a slot-die nozzle and multiple nozzles for faster, more uniform material deposition, making the process scalable for industrial production. Using wheat straw not only reduces environmental impact by lowering emissions and decreasing agricultural waste but
materials3D-printingthermal-insulationsustainable-materialswheat-strawbiomasseco-friendly-materialsLive bacteria-infused sustainable building material traps CO2 from air
Researchers at ETH Zurich have developed an innovative, sustainable building material infused with live cyanobacteria that actively captures atmospheric carbon dioxide through photosynthesis and biocementation. This 3D-printed hydrogel-based material houses photosynthetic bacteria within a polymer network designed to optimize light, CO2, water, and nutrient flow, enabling the bacteria to remain productive for over a year. The material sequesters CO2 both biologically and by forming stable mineral carbonates, which strengthen the initially soft gel into a robust, hardened structure over time. Laboratory tests demonstrated that the material can bind approximately 26 milligrams of CO2 per gram, outperforming typical biological methods and rivaling chemical mineralization in recycled concrete. The technology has moved beyond the lab, with large-scale installations such as the "Picoplanktonics" exhibit at the Architecture Biennale in Venice, featuring three-meter-high structures capable of capturing up to 18 kilograms of CO2 annually—comparable to a mature pine tree.
materialssustainable-buildingcarbon-captureliving-materialscyanobacteria3D-printingbiocementationNew 3D-printed off-roading robot made from recycled materials
A European collaboration between Lemki Robotix (Ukraine), iSCALE 3D (Germany), and Zeykan Robotics (Czech Republic) has unveiled the world’s first fully 3D-printed autonomous off-road robot made entirely from recycled materials. The robot’s body, wheels, and rims are fabricated using reinforced recycled polymers—glass fiber-reinforced recycled polypropylene for the sealed body, puncture-proof recycled polyurethane for airless wheels, and carbon fiber-reinforced nylon for rims—ensuring durability in harsh outdoor environments. Equipped with 360° cameras, LiDAR, and Starlink satellite connectivity, it supports real-time remote operation and autonomous navigation via an onboard neural network, capable of functioning even in GPS-denied areas. Designed for challenging applications such as military logistics, search and rescue, precision agriculture, and infrastructure inspection, the hermetically sealed robot can cross shallow water and operate reliably in demanding conditions. This project exemplifies the potential of large-format 3D printing to
robot3D-printingrecycled-materialsautonomous-robotoff-road-robotsustainable-roboticsneural-networksAI co-designs a jumping robot that outperforms its human-made twin
Researchers at MIT’s Computer Science & Artificial Intelligence Laboratory (CSAIL) have developed a novel system leveraging generative AI, specifically diffusion models, to co-design robots by optimizing their mechanical structures through iterative simulation and fabrication. This approach allows users to input a 3D model and specify modifiable components, enabling the AI to generate and test numerous design variants before physical production. In a key demonstration, the AI-designed jumping robot outperformed a human-designed counterpart by jumping 41% higher, achieved through innovative curved, drumstick-like linkages that were lighter yet stronger and had greater energy capacity. Additionally, the AI improved the robot’s foot design, enhancing landing stability by 84%, significantly reducing falls. This breakthrough highlights the potential of diffusion models to reveal new insights into structural physics and accelerate hardware design processes, which traditionally lag behind software development due to complexity and manufacturing constraints. By balancing competing objectives such as jump height and landing success, the AI system produced optimized designs that blend human intuition with machine precision.
roboticsAI-designgenerative-AI3D-printingrobot-optimizationdiffusion-modelsrobotic-hardwareFirst-time maker’s 3D-printed drone could fly 130 miles in 3 hours
Engineer Tsung Xu, a first-time maker with no formal background in aerodynamics or 3D printing, successfully designed and built a fully functional vertical takeoff and landing (VTOL) fixed-wing drone capable of flying 130 miles (209.2 km) in about 3 hours. Completed in just 90 days, Xu’s project involved designing, modeling, and 3D printing every aerodynamic surface and structural component from scratch using a consumer-grade Bambu Lab A1 desktop 3D printer. Non-printable elements such as motors, radio equipment, and electronic speed controllers were sourced separately and integrated into the system, which is powered by a high-energy-density lithium battery to maximize endurance. The drone’s VTOL capability allows it to take off and land vertically without a runway, then transition to efficient forward flight, a feature typically found in advanced military or commercial unmanned aerial systems. Xu’s achievement demonstrates how accessible technologies like desktop 3D printing and off-the-shelf components can enable
robotdrone3D-printinglithium-batteryVTOLaerospace-engineeringunmanned-aerial-systemsWorld's first test shakes 3D-printed homes to check earthquake safety
The University of Bristol has conducted the world’s first large-scale earthquake safety test on a 3D-printed concrete home using the UK’s largest shaking table. This experiment aimed to evaluate whether 3D-printed homes can withstand seismic forces, addressing concerns about the structural integrity of this emerging construction method. By subjecting a quasi-real-scale 3D-printed concrete unit to progressively intense shaking, researchers closely monitored its response to identify potential weaknesses such as cracking or displacement. The goal is to compare 3D-printed structures with traditional buildings, validate computational seismic models, and ultimately determine if 3D-printed concrete can meet current earthquake safety standards. The project, led by Dr. De Risi, seeks to optimize design parameters like layer bonding and reinforcement integration to improve seismic performance. These findings are intended to inform engineers, architects, and policymakers, potentially leading to new building codes that incorporate additive manufacturing technologies. As 3D printing gains popularity for its affordability and sustainability, this research addresses
3D-printingearthquake-safetyconstruction-technologymaterials-scienceconcrete-innovationseismic-testingadditive-manufacturingUK inventor's Transformers-styled robot becomes shape-shifting vehicle
British inventor James Bruton has created a functional, rideable Transformer-style robot that can smoothly shift between humanoid and vehicle forms. Unlike many previous Transformer replicas that lack passenger space, Bruton's design allows him to ride the robot like a kid’s Power Wheels car. The robot incorporates 16 motors—including RC servos, Dynamixel servos, and DC brushed motors—and uses a Teensy microcontroller to control folding body panels, wheel movement, and LED lighting. Its legs are primarily decorative, and the robot folds into a fully operational electric vehicle capable of carrying Bruton at modest speeds. Bruton’s invention showcases practical engineering with a focus on stability, reliability, and refined aesthetics. The robot’s lightweight aluminum extrusion frame supports significant weight while maintaining nimbleness, and 3D printing has enabled rapid design iteration. To address challenges like shifting center of gravity during transformation, Bruton implemented a robust suspension system and balanced weight distribution. While the robot cannot yet walk in humanoid form, it represents
robotroboticselectric-motors3D-printingmicrocontrollershape-shifting-vehicleengineering-innovationUS scientists develop real-time defect detection for 3D metal printing
Scientists from Argonne National Laboratory and the University of Virginia have developed a novel method to detect defects, specifically keyhole pores, in metal parts produced by 3D printing using laser powder bed fusion. Keyhole pores are tiny internal cavities formed when excessive laser energy creates deep, narrow holes that trap gas, compromising the structural integrity and performance of critical components such as aerospace parts and medical implants. The new approach combines thermal imaging, X-ray imaging, and machine learning to predict pore formation in real-time by correlating surface heat patterns with internal defects captured via powerful X-rays. This method leverages existing thermal cameras already installed on many 3D printers, enabling instant detection of internal flaws without the need for continuous expensive X-ray imaging. The AI model, trained on synchronized thermal and X-ray data, can identify pore formation within milliseconds, allowing for immediate intervention. Researchers envision integrating this technology with automatic correction systems that adjust printing parameters or reprint layers on the fly, thereby improving reliability, reducing waste, and enhancing safety in manufacturing mission-critical metal parts. Future work aims to expand defect detection capabilities and develop repair mechanisms during the additive manufacturing process.
3D-printingmetal-additive-manufacturingdefect-detectionmachine-learningthermal-imagingX-ray-imagingmaterials-scienceUS turns recycled scrap into 3D-printed rocket parts with AI boost
robotmaterials3D-printingAIadditive-manufacturingrecycled-materialssustainable-manufacturingUS Army creates 3D-printed skin to heal combat wounds, fight bugs
materialsbioprintingbiomaterialsbiomedical-technologies3D-printingmilitary-technologytissue-engineeringUS nuclear fusion gets a 3D printing boost to fast-track construction
energynuclear-fusion3D-printingconstructionplasma-physicsmagnet-systemsNSTX-UNew human spine-inspired neck could revolutionize humanoid robots
robothumanoid-robotsanimatronicsengineering3D-printinglinear-actuatorsartificial-spinePhotos: World's tallest 3D-printed tower blends tech, art, and climate
robotics3D-printingdigital-designarchitectureconstruction-technologyCO₂-capturematerials-scienceCan the Cadillac Celestiq EV make GM’s luxury brand great again? Don’t rule it out
energyelectric-vehicleCadillacluxury-carbattery-technologyautomotive-design3D-printingCan the Celestiq EV make Cadillac great again? Don’t rule it out
electric-vehicleEVbattery-technologyluxury-carsautomotive-design3D-printingCadillacHugging Face releases a 3D-printed robotic arm starting at $100
Hugging-Facerobotic-arm3D-printingprogrammable-roboticsAI-technologyLeRobotSO-101