3d printing and other digital manufacturing

An engineer’s guide to understanding the state
of the art in metal 3D Printing

Metal 3D Printing Technology Report

The 4th International 4D Materials Design and Additive Manufacturing Conference 2025 (4DMDA 2025) is organized by A*STAR's Research Institutes, Universities, and the 4D Printing Society. <a href="https://4dprintings.com/events/4dmda2025/" id="isPasted" class="button-main-action">REGISTER HERE</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQyNTU2MjAxMDEwLUFTVEFSLTREUC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px" class="fr-fic fr-dib" />The event showcases the latest developments and technologies in smart materials, metamaterials, intelligent designs, modelling, additive manufacturing, and 3D/4D printing. It addresses current concerns in the further development of 3D/4D printed devices. It provides a forum for internationally recognized experts and young scientists working in the fields of smart materials, metamaterials, advanced design, modelling and simulation, and 3D/4D printing technologies to present their work.This conference is hosted in person at the Advanced Remanufacturing and Technology Centre (ARTC), Singapore, and is scheduled to take place on July 8-10, 2025.<a href="https://4dprintings.com/events/4dmda2025/" class="button-main-action">REGISTER HERE</a>

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

EVENT: 4D Materials Design and Additive Manufacturing Conference 2025

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.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]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.<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" /><h2>The Role of Nanomaterials in 3D Electronics Printing</h2>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.In short, nanomaterials consist of two main components:<ol><li>An easily printable matrix material. In extrusion printing, this might be an ordinary thermoplastic polymer; in dispensing it may be a glycol or glycol ether, for example.</li><li>A significant concentration of nanoparticles. These are the critical functional ingredients of the nanomaterial and may be of a material such as silver, copper, or carbon.</li></ol>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]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.<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" /><h2>Multi-Material Circuits: Expanding the Horizons</h2>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.<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.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.<h2>The Future of 3D Electronics Printing</h2>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.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.<h2>Resources</h2>[1] Persad J, Rocke S. A survey of 3D printing technologies as applied to printed electronics. Ieee Access. 2022 Mar 8;10:27289-319.[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.

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

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.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.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.3D printing approach strings together cable-driven mechanisms for you Video: MIT CSAILIn 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.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.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.<h2>A new twist on cable-driven fabrication</h2>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.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.<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.  Image courtesy of the researchers.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.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.<h2>Driving unique designs across robotics, art, and beyond</h2>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.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.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.“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.”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.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.

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

3D printing is gaining increased traction in the defense sector as its unique advantages can be leveraged to provide fast, cost-effective manufacturing solutions.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.<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.<h2>Benefits of 3D printing in defense</h2>There are 5 main benefits that offer key advantages for defense applications:<h3>On-demand spare parts production</h3>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.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.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742369309404-the-royal-netherlands-navy-fleet-of-printers+%281%29.webp" /><h3>Reduced logistical challenges</h3>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.<h3>Wide range of materials</h3>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.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.<h3>Faster maintenance and repairs</h3>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.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.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742369345602-Air-Force-blog-image-1.webp" /><h3>Digital inventory and remote print management</h3>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.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.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.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742369378494-1742369378494.png" /><h2>Expanding applications beyond logistics and maintenance</h2>While 3D printing has proven its value in defense logistics, maintenance, and supply resilience, its versatility can extend even further.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.By integrating 3D printing into defense workflows organizations can improve readiness, reduce logistical strain, and ensure adaptability in an ever-changing landscape.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>

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

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. <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><a href="https://info.mesago.de/-lp/5HKPB14784/p4jkP173" target="_blank" id="isPasted" class="button-main-action">Sign up here</a></td></tr></tbody></table>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.<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<h2>Ideation and design</h2>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.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.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.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQyMjg2ODM3ODc4LVRyYWRlc2hvdy53ZWJwLjEyODAud2VicCIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" class="fr-fic fr-dii" />Exhibition stand designed with AI. Image: James Woodcock<h2>Defining the build</h2>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.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.<h2>AI as QA </h2>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.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.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQyMjg2ODY1MTQ0LVJvYm90LndlYnAuMTI4MC53ZWJwIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii" />AI also helps to monitor and maintain machines. Image: James WoodcockPerennial 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.<h2>Future failure alert</h2>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. <h3>Explanation of terms</h3>Machine Learning           A subset of AI focused on building systems that learn from data to make predictions or decisions without being explicitly programmed for each task.Deep LearningA 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.Generative Models       AI models designed to generate new data samples that resemble the training data. These models can create new text, images, music, or other content.Neural Networks A set of algorithms modelled loosely after the human brain, designed to recognize patterns.<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><a href="https://info.mesago.de/-lp/5HKPB14784/p4jkP173" target="_blank" rel="nofollow" class="button-main-action">Sign up here</a></td></tr></tbody></table>

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

The next hype cycle?

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

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

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

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

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

Orca Slicer vs. Cura: A Technical and Practical Comparison

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

Podcast: 3D Printing Robot Muscles

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

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

What are Flexible Hybrid Electronics (FHE)?

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

3D Printing in Education: From Classroom to the Workplace

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

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

INJECTION MOLDING GUIDELINES WITH 3D PRINTED MOLDS

<html><head></head><body>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;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;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;<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">Photo by Rob Wingate on Unsplash<h2>What Are Nanomaterials?&nbsp;</h2>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;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.<h2>3D Printing Nanomaterials: Challenges and Outlook</h2>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;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;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;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;<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;<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">Photo by Andrea G on Unsplash<h2>The Future of 3D Printing is Nanomaterials</h2>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;<hr><h3>Resources&nbsp;</h3>[1] Astaneh ME, Fereydouni N. Silver Nanoparticles in 3D Printing: A New Frontier in Wound&nbsp; Healing. ACS omega. 2024 Sep 16;9(40):41107-29. [2] Bajpai A, Jain PK. Investigation on 3D printing of graphene and multi-walled carbon&nbsp; nanotube mixed flexible electrically conductive parts using fused filament fabrication. Journal of&nbsp; Materials Engineering and Performance. 2023 Jul;32(14):6319-28. [3] OSU research focuses on improving fire safety in 3D-printed materials [Internet]. Oklahoma&nbsp; State University, January 30, 2025.&nbsp;https://news.okstate.edu/articles/engineering-architecture- technology/2025/ osu_research_focuses_on_improving_fire_safety_in_3d_printed_materials.html#h_6010598121 71738267359042 [4] Formlabs’ Premium Teeth Resin Receives FDA 510(k) Clearance for Temporary Crowns and Bridges [Internet]. Formlabs, August 6, 2024.&nbsp; https://dental.formlabs.com/company/press/premium-teeth-resin-receives-fda-clearance- temporary-crowns-and-bridges/</body></html>

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

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

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

Podcast: Dehumidifying Walls Help Switzerland Hit Net Zero By 2050

<h2 id="isPasted">3D printer lifespan: Factors to consider</h2>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.<h2>3D printer usage</h2>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.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.<h3>Some general points to consider:</h3>Print Volume and Duration: 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.Materials Used: 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.User Proficiency: 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.<h2>Print environment</h2>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.<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">When considering&nbsp;temperature&nbsp;and&nbsp;humidity we need to ensure the following:<ul><li>Consistent temperatures: 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>Humidity control: 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>Consistent airflow: 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>Dust and contaminants: 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>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.Less known factors are&nbsp;vibrations and stability, often overlooked the surface you place your printer on is an important element in your 3D printer’s lifespan.<ul><li>Solid surface: 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>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.<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"><h3 id="isPasted">Routine cleaning</h3>We briefly touched on the subject earlier, but cleaning extends to several other parts besides the print bed:<ul><li>Nozzle and extruder: 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>Build plate: 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>Fans&nbsp;and filters: 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>Moving parts: 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>Axis calibration: 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>While this is a step that is sometimes overlooked, firmware and software updates can do a lot to extend your 3D printer’s lifespan.<ul><li>Firmware: 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>Software: 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>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.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.<h3>Frame and structural integrity</h3><ul><li>Rigid construction: 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>Linear bearing and rails: 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>Drive gears: 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>Nozzles and print cores: 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>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;long-term ROI.<ul><li>Cost-benefit analysis: 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>Scalability: 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>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.All of these features work towards extending the lifespan of a 3D printer and directly affect some of the factors we’ve previously outlined.<h3>Automated bed leveling and calibration</h3>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.<h3>Automated material handling</h3>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.<h3>Print process reporting and error detection</h3>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.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.<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"><h3 id="isPasted">Modularity</h3>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.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.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.<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"><h3 id="isPasted">Software integration and ecosystems</h3>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.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.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.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.The key takeaway is that the integration of 3D printers within an ecosystem has contributed a lot towards extending their lifespan and serviceability.<h2>UltiMaker: Built to perform, built to last</h2>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.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.<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">

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

This article delves into the essential roles that jigs and fixtures play in streamlining manufacturing processes.

Jigs and Fixtures: Design, Production, Applications

Warping occurs when 3D printed parts curl away from the build plate

Warping is typically caused by poor bed adhesion and inconsistent printing temperatures. Here’s how to fix the 3D printing problem.

3D Print Warping (PLA, PETG, ABS): 6 Simple Fixes

Additive Manufacturing (AM), or 3D printing, marks a shift from traditional subtractive methods to a layer-by-layer approach that builds physical objects directly from digital models. Originally used for prototyping, AM has evolved into a viable production tool across industries such as aerospace, automotive, medical, and consumer products. It utilizes material forms like filament, resin, or powder to create complex parts with a high level of speed and material efficiency.AM’s core benefits include unmatched design freedom, rapid prototyping, reduced material waste, and potential for mass customization. Among the seven AM process categories defined by ISO and ASTM, this guide focuses on key technologies relevant to engineers: Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS), Multi Jet Fusion (MJF), and Direct Metal Laser Sintering (DMLS), also called Selective Laser Melting (SLM).This guide is tailored for design and hardware engineers aiming to produce functional AM parts. It covers the relationship between process, material, and geometry, while introducing essential Design for Additive Manufacturing (DfAM) rules. Topics include material selection, CAD-to-print workflow, advanced design techniques, post-processing, and common pitfalls—empowering users to fully leverage AM's capabilities.<h2>Design for Additive Manufacturing</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1745310443307-3d_printer_design_process.jpg" style="width:100%px" class="fr-fic fr-dib" alt="dfam" />DfAM ensures parts are designed to suit the 3D printing processDesign for Additive Manufacturing (DfAM) is vital for engineers aiming to harness the full potential of their 3D printer. Unlike traditional Design for Manufacturability (DfM), which suits subtractive or formative processes, DfAM emphasizes functional geometry and material efficiency—adding material only where needed. It takes advantage of additive’s strengths, including geometric freedom and part consolidation.Common 3D CAD or 3D modeling software tools like SolidWorks, Fusion 360, and Siemens NX serve as DfAM foundations. Advanced features such as mesh editing, topology optimization, lattice structures, and simulation tools help optimize designs for printability, strength, and efficiency. Direct modeling enables fast iterations tailored to AM-specific constraints.Key design rules for printed parts include maintaining appropriate wall thickness—typically over 0.8 mm for FDM, and 0.4–0.5 mm for SLA. Powder-based methods like SLS and DMLS have their own minimums. Proper orientation affects strength, accuracy, and support needs. Minimizing build height shortens print time, while aligning critical features with the build direction can improve mechanical performance.Overhangs over 45° in FDM and DMLS usually need support, whereas powder-bed systems like SLS are more forgiving. And features such as chamfers, fillets, and teardrop holes can reduce or eliminate support requirements. Bridges and small unsupported spans are limited—typically around 5 mm in FDM and 2 mm in DMLS.3D printers also have limits in terms of detail: small features like holes and pins need careful sizing—minimum 1 mm in FDM, smaller in SLA or DMLS. Threads are often better added post-print, while clearances are crucial to avoid fused parts, especially in tight-fitting or moving assemblies.<h3>DfAM Summary Table</h3><table><tbody><tr><td>Design Element</td><td>Guideline Summary</td></tr><tr><td>Wall Thickness</td><td>Min. varies by process: FDM &gt;0.8mm, SLA ~0.4–1.0mm, SLS/MJF ~0.7–1.0mm, DMLS ~0.8–1.2mm. Keep consistent.</td></tr><tr><td>Part Orientation</td><td>Affects strength, surface finish, support needs, print time, and thermal stress (esp. PBF processes).</td></tr><tr><td>Overhangs</td><td>Limit ~45° for FDM/DMLS; SLA often needs support regardless; SLS/MJF usually don’t need supports.</td></tr><tr><td>Bridges</td><td>Max unsupported span: FDM ~5mm, DMLS ~2mm; SLA often requires support.</td></tr><tr><td>Supports</td><td>Needed in FDM, SLA, DMLS; avoid hard-to-remove areas; minimize using fillets/chamfers.</td></tr><tr><td>Holes</td><td>FDM &gt;1mm, SLA ~0.5–0.8mm, SLS ~1.5mm, DMLS ~1mm; vertical holes more accurate; undersized—may need drilling.</td></tr><tr><td>Escape Holes</td><td>Needed in hollow parts to drain resin/powder: SLA ~3.5mm, DMLS ~2–5mm.</td></tr><tr><td>Pins &amp; Small Features</td><td>FDM &gt; nozzle size, SLA ~1mm, SLS ~0.8mm, DMLS ~1–1.5mm; add fillets, watch aspect ratios.</td></tr><tr><td>Clearance &amp; Tolerances</td><td>SLA: snug fit ~0.1–0.2mm; SLS/MJF ~0.2–0.6mm; DMLS ~0.3–0.6mm. Leave room for machining on critical fits.</td></tr><tr><td>Threads</td><td>Prefer inserts or tapping; coarse threads (M6+) may be printable; ensure proper clearance.</td></tr><tr><td>Text &amp; Fine Details</td><td>Min. feature size: FDM &gt;1mm, SLA ~0.1–0.5mm, SLS/DMLS ~0.3–1mm. Use bold, sans-serif fonts.</td></tr><tr><td>Fillets &amp; Chamfers</td><td>Reduce stress and support needs; avoid sharp corners; keep wall thickness consistent.</td></tr><tr><td>Ribs &amp; Gussets</td><td>Add for strength/stiffness without bulk; rib thickness ~60% of wall; brace large flat areas.</td></tr></tbody></table><h2>Material Selection and Design</h2>Selecting the right material in additive manufacturing (AM) directly affects the design of a part. Material properties—such as stiffness, strength, thermal resistance, and chemical compatibility—determine how the part will perform and how it should be designed. For example, a flexible material like TPU requires different design considerations compared to a rigid material like Nylon or a high-performance material like PEI. The material guides key design features, including wall thickness, support structures, and part orientation.Material-driven design considerations include:<ul><li>Support structures: Materials that warp, such as ABS, may need more support or a specific part orientation to avoid defects.</li><li>Part orientation: Strong materials like PEI benefit from adjusting orientation to maximize strength and reduce warping.</li><li>Surface finish: SLA resins often need smoother finishes, so designs may require specific supports that are easy to remove without damage.</li></ul>Besides strength and flexibility, a material’s behavior during printing influences design decisions. Thermoplastics like ABS may warp or shrink when cooling, which could require thicker walls, specific orientations, or the use of a heated bed to prevent issues.[1] On the other hand, SLA resins are more brittle, so designs need more uniform wall thicknesses and effective support structures to avoid breakage. Nylon and PETG, often used for functional parts, need designs that account for stress distribution and long-term durability.For metal materials such as stainless steel or titanium, design must account for factors like thermal conductivity and internal stress. Metal parts may need specific adjustments for post-processing, such as heat treatment.Recommended reading: <a href="https://www.wevolver.com/article/understanding-cad-file-types-a-comprehensive-guide-for-digital-design-and-hardware-engineers" target="_blank">Understanding CAD File Types: A Comprehensive Guide for Digital Design and Hardware Engineers</a><h2>Designing 3D Prints Step by Step</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1745310457398-cad_engineers_discussing_design.jpg" style="width:100%px" class="fr-fic fr-dib" alt="3d design" />3D design software can be difficult to use for beginnersDesigning a 3D print using a CAD program or other design software involves several steps, from selecting the right software to exporting a print-ready file. This guide breaks down the process into clear, simple steps.<h3>1. Choose the Right CAD or Modeling Software</h3>Your 3D design journey starts with picking the appropriate software. For beginners, Tinkercad is an excellent browser-based tool with drag-and-drop functionality. It’s ideal for basic models like keychains, nameplates, or simple enclosures. For more advanced users, Fusion 360, SolidWorks, Blender, or FreeCAD offer powerful modeling tools for engineering parts, artistic models, and assemblies. Fusion 360, in particular, strikes a good balance between ease of use and professional features like parametric design and simulation.<h3>2. Define the Purpose of the Part</h3>Before modeling, consider what your part is for. Will it be decorative, structural, mechanical, or wearable? Understanding its function will help determine what material you’ll use and how strong or flexible the part must be. For example, parts under stress need thicker walls or reinforced features, while a simple figurine can be hollow and lightweight.<h3>3. Model the Object Thoughtfully</h3>Using your chosen software, start building the object using basic shapes or sketch-based geometry. (Further modelling basics are explained in the next section.) Keep these tips in mind:<ul><li>Use consistent units (mm or inches) and precise dimensions.</li><li>Maintain minimum wall thickness (typically 0.8 mm or more for FDM printing).</li><li>For snap-fit parts or enclosures, leave clearance gaps—about 0.2–0.5 mm is typical depending on your printer’s accuracy.</li><li>Avoid sharp inside corners, which can be hard to clean or print accurately.</li></ul><h3>4. Account for Overhangs and Bridges</h3>Overhangs are features that extend outward and are not supported beneath. Most printers struggle with overhangs greater than 45°, and bridges (horizontal spans) beyond 5 mm may sag if unsupported.[2] Use techniques like:<ul><li>Chamfers instead of sharp 90° overhangs.</li><li>Teardrop or diamond-shaped holes instead of circular holes in horizontal surfaces.</li><li>Design parts in a way that minimizes the need for external supports.</li></ul><h3>5. Add Details with Printability in Mind</h3>Text, holes, pins, and small features should be sized with the printer's resolution in mind:<ul><li>Text should be at least 0.4 mm high and 0.5 mm wide to remain legible.</li><li>Holes should be ≥ 1 mm for clean resolution.</li><li>Avoid overly fine threads—use inserts or post-processing to add threads for mechanical parts.</li></ul><h3>6. Design for Print Orientation and Strength</h3>Orientation affects strength, surface quality, and print time. For FDM prints:<ul><li>Parts are strongest along the layer lines, so align structural elements accordingly.</li><li>Orient large, flat surfaces parallel to the build plate to prevent warping.</li><li>Hollow or enclosed shapes should include escape holes for trapped resin or powder in SLA/SLS processes.</li></ul><h3>7. Export the Model for Printing</h3>When your design is complete, export it in a 3D printable format, typically STL or 3MF. An STL file is the most common but does not include color or material data. 3MF is more modern and can store additional information like print settings or units.<h3>8. Slice the Model Using Slicing Software</h3>Use a slicer like Ultimaker Cura, PrusaSlicer, or Bambu Studio to prepare the model for printing. The slicer converts your 3D model into layers and generates G-code, which your printer reads to know how to move.[3] Key settings include:<ul><li>Layer height (affects detail and print speed)</li><li>Infill density (affects strength and weight)</li><li>Supports (for overhangs)</li><li>Brim or raft (for bed adhesion)</li></ul><h3>9. Save and Print</h3>Once slicing is complete, save the G-code file to an SD card or send it to your printer wirelessly (if supported). Monitor the first layers carefully to ensure good bed adhesion, which is critical for a successful print.Recommended reading: <a href="https://www.wevolver.com/article/how-to-make-a-3d-model-for-printing" target="_blank">How to Make a 3D Model for Printing</a><h2>3D Modelling Basics</h2>Creating a 3D print-ready part begins with establishing the basic shape in your CAD software. First, start by sketching a 2D profile of the part on a selected plane, using tools like line, circle, or rectangle to define its outline. Once the basic sketch is ready, use features like "extrude" or "revolve" to convert the 2D sketch into a 3D object, adding depth or curvature. For more complex geometries, you can combine multiple sketches or use Boolean operations to add or subtract material.After establishing the main body of the part, refine the design with features like holes, fillets, or chamfers. Holes can be created with the "extruded cut" tool, ensuring they have the correct diameter for the intended functionality. Fillets and chamfers can be added to edges to improve strength or ease of assembly. It’s also important to consider the thickness of walls, as parts that are too thin might not print well or could fail under stress. Many CAD tools allow you to measure wall thickness directly or display warnings for parts that fall below a certain threshold.Using the "mirror" or "pattern" tools can help replicate symmetrical parts or structures without manually redesigning them. Additionally, optimizing internal features, such as adding ribs or lattice structures, can strengthen the part while reducing material use.<h2>Advanced 3D Printing Design Strategies</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1745310478211-3d_printed_structure_design.jpg" style="width:100%px" class="fr-fic fr-dib" alt="lattice" />Lattice structures are often deployed in aerospace metal AMAdvanced design strategies in additive manufacturing (AM) go beyond basic printability to unlock the full potential of 3D printing. These techniques—topology optimization, generative design, lattice structures, and integrated geometries—allow for complex designs for parts that are lighter, stronger, and more efficient than those made with traditional manufacturing.Topology optimization and generative design use software to remove unnecessary material or generate multiple design options within defined constraints. Engineers input load conditions, boundary limits, and performance goals (e.g., minimizing weight or maximizing stiffness), and the software outputs organic-looking geometries optimized for performance. These designs are ideal for AM, which can produce their complex shapes with ease. They’re commonly used in aerospace, automotive, and robotics for lightweighting and part consolidation—replacing multi-part assemblies with a single, optimized component.Lattice structures are intricate 3D frameworks made from repeating cells like gyroids or tetrahedrons. They drastically reduce weight while maintaining structural integrity.[4] Lattices can be tailored for specific stiffness, strength, or energy absorption, and even used for specialized applications like heat exchangers, sound dampening, or bone implants. However, they must be designed with the printing process in mind—ensuring that powder or resin can be removed from inside and that minimum printable strut thicknesses are met.Complex geometries and part integration represent another strength of AM. Parts can include internal channels for fluid flow or conformal cooling in tooling, eliminating the need for traditional drilling or welding. Enclosures for electronics can include integrated features like vents, mounts, and cable guides in a single print. Engineers often turn to biomimicry for design inspiration, emulating efficient natural structures.<h2>Conclusion</h2>3D printing represents a major shift in engineering, allowing the creation of complex, optimized parts that are difficult or even impossible to produce using traditional manufacturing methods. Additive manufacturing’s ability to build geometrically intricate and functionally efficient structures gives designers more freedom, especially in fields like aerospace, automotive, and healthcare, where lightweight and high-performance parts are often needed.To make the most of these possibilities, designers need a solid understanding of both the design principles and the limitations of 3D printing technologies. Design for Additive Manufacturing (DfAM) ensures that parts are not only functional but also printable without issues like warping or weakness. Factors such as wall thickness, part orientation, and support structures need careful attention to produce reliable and high-quality prints.By combining advanced software with a sound understanding of AM processes, engineers can design parts that push the boundaries of what's possible. And as 3D printing continues to improve, its role in product design will only grow, offering more ways to create efficient, creative, and sustainable solutions.<h2>References</h2>[1] Ramian J, Ramian J, Dziob D. <a href="https://www.mdpi.com/1996-1944/14/22/7070" target="_blank">Thermal deformations of thermoplast during 3D printing: warping in the case of ABS</a>. Materials. 2021 Nov 21;14(22):7070.[2] Jiang J, Stringer J, Xu X, Zhong RY. <a href="https://www.tandfonline.com/doi/abs/10.1080/0951192X.2018.1466398" target="_blank">Investigation of printable threshold overhang angle in extrusion-based additive manufacturing for reducing support waste</a>. International Journal of Computer Integrated Manufacturing. 2018 Oct 3;31(10):961-9.[3] Coburn J. <a href="https://www.makeuseof.com/wp-content/uploads/2017/03/Ultimate-Beginner%E2%80%99s-Guide-to-3D-Printing.pdf" target="_blank">Ultimate Beginner’s Guide to 3D Printing</a> [Internet]. 2017[4] Chouhan G, Bala Murali G. <a href="https://journals.sagepub.com/doi/abs/10.1177/09544089231160030" target="_blank">Designs, advancements, and applications of three-dimensional printed gyroid structures: a review</a>. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering. 2024 Apr;238(2):965-87.

This article looks at how to design 3D prints by mastering the principles and practices of designing for additive manufacturing (DfAM), from fundamental concepts to advanced techniques.

How to Design 3D Prints: Software, DfAM, Advanced Strategies

3D printing, especially Fused Deposition Modeling (FDM/FFF), has made it fast and affordable to create customized parts for all kinds of uses, including items that come into contact with food. From cookie cutters and chocolate molds to components used in food packaging or processing, the appeal of quick, low-cost prototyping is clear.But just because a 3D printing filament is labeled “food-safe” doesn’t mean your finished print automatically is. That’s a common misconception. In reality, making a 3D printed object truly safe for food contact involves a lot more than picking the right material. You need to consider the entire process—what’s in the food-safe filament (including additives), what type of nozzle and printer you use during FDM 3D printing, how clean the print is, whether it’s sealed properly, and how the item will be cleaned and used.This guide takes a clear, practical look at what it really takes to 3D print food-safe parts using food safe 3D printer filament. We’ll break down what terms like “food-grade” and “food-safe” actually mean, explain the regulations in the US and EU, compare popular filaments, and walk through key risks like porosity and chemical leaching. Most importantly, we’ll outline the best practices that engineers, makers, and product designers can follow to reduce those risks and build safer, more reliable prints for food contact.<h2>Defining "Food Safe" in 3D Printing</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1748275164942-food_prep_containers_vegetables.jpg" style="width:100%px" class="fr-fic fr-dib" alt="thermoplastic" />Certain thermoplastics are suitable for 3D printed food productsUnderstanding terminology is important when discussing food contact applications in additive manufacturing. The terms "food grade" and "food safe" are often used interchangeably, but they carry distinct meanings, especially within the context of 3D printing processes:<ul><li>Food Grade: This term typically applies to the raw material itself, such as the filament spool before printing. It signifies that the material composition is considered suitable for human consumption or is permitted to come into direct contact with food products under specific regulations.</li><li>Food Safe: This term is more relevant to the finished article or the 3D printed part. A food-safe object is one that, when used as intended, will not create a safety hazard. This assessment encompasses not only the raw material but also the manufacturing process (i.e., 3D printing) and the final properties of the printed object, including its surface characteristics and potential for leaching or contamination.</li></ul>The distinction for engineers is that procuring a "food grade" or "FDA compliant" food safe 3D printer filament is only the first step and does not automatically make printed objects safe for food use. The additive manufacturing process itself introduces factors like surface porosity and potential contamination that need to be addressed separately.Drawing from established food safety principles and regulatory guidelines (such as those referenced by the FDA Food Code and EU regulations), materials intended for food contact must generally meet the following criteria:<ol><li>Non-Toxic: They must not transfer their constituents (leachables or migrants) into food at levels that could endanger human health.</li><li>Organoleptically Neutral: They must not impart undesirable colors, odors, or tastes to the food.</li><li>Durable and Resistant: They need to be durable, corrosion-resistant, and able to withstand the environment of their intended use, including exposure to different food types (acidic, fatty), temperatures, and cleaning procedures.</li><li>Non-Absorbent: The material should resist absorbing moisture or food components.</li><li>Smooth and Easily Cleanable: This is a particularly challenging criterion for 3D printing. Food contact surfaces must be finished to have a smooth texture, free from breaks, cracks, chips, sharp internal angles, or crevices where microorganisms can grow.</li></ol>Recommended reading: <a href="https://www.wevolver.com/article/is-pla-food-safe" target="_blank" rel="noopener noreferrer">Is PLA Food Safe?</a><h2>Regulations for Food Safe 3D Printer Filament</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1748275176359-fda_headquarters_sign.jpg" style="width:100%px" class="fr-fic fr-dib" alt="fda" />The FDA regulates food-safe materials in the United StatesBecause of the safety hazards involved, food safe 3D printer filament is governed by a host of regulations, and it’s important to know how to interpret these regulations to ensure product safety and compliance. The United States and the European Union share the goal of protecting consumer health, but their regulatory frameworks differ in structure and implementation.<h3>US FDA Framework</h3>In the U.S., the Food and Drug Administration (FDA) oversees food contact materials under the Federal Food, Drug, and Cosmetic (FD&amp;C) Act. A Food Contact Substance (FCS) is any material component likely to migrate into food. Compliance is determined based on all potentially migrating substances, not just the base polymer, including residual monomers, additives, and processing aids.Key regulatory pathways include:<ul><li>Food Additive Regulations (21 CFR Parts 174–179), particularly Part 177 for polymers.[1]</li><li>GRAS (Generally Recognized As Safe) status, either by historical use or scientific review.</li><li>Prior Sanctioned Substances, approved before 1958 (21 CFR Part 181).</li><li>Threshold of Regulation (TOR) exemption for substances with negligible migration (below 0.5 ppb).</li><li>Food Contact Substance Notification (FCN), the primary mechanism for new substances, where approval is specific to the applicant.</li></ul>FDA compliance claims must be specific—generic labels like "food grade" are insufficient without citing exact regulations. Manufacturers typically provide technical datasheets referencing relevant CFR titles. Importantly though, Safety Data Sheets (SDS) do not confirm regulatory compliance.<h3>EU Framework</h3>The EU's primary regulation is EC No 1935/2004, which requires food contact materials (FCMs) not to harm health, alter food composition, or affect taste and odor.[2] This is supported by Regulation (EC) No 2023/2006 on Good Manufacturing Practices (GMP), and specifically for plastics, Commission Regulation (EU) No 10/2011.Key elements include:<ul><li>Union List (Positive List) of permitted substances in Annex I.</li><li>Migration Limits, including:<ul><li>Overall Migration Limit (OML) of 10 mg/dm².</li><li>Specific Migration Limits (SMLs) for individual substances.</li></ul></li><li>Migration Testing using food simulants under worst-case conditions.</li><li>Declaration of Compliance (DoC), a mandatory document confirming regulatory conformity, required throughout the supply chain.</li></ul><h3>Certification and Manufacturer Responsibility</h3>Ensuring compliance is the manufacturer’s duty. Engineers selecting 3D printing materials should prioritize technical datasheets that cite specific regulatory standards (e.g., FDA 21 CFR 177 or EU 10/2011). However, "compliance" differs from formal "certification." While compliance may be self-declared based on ingredient data, certification often involves comprehensive testing and third-party validation.[3]In both regions, due diligence is needed to account for all potential migrants, including non-intentionally added substances (NIAS). The complex and layered regulatory environment requires expert knowledge, which makes production of certain printed food products difficult.<h2>List of Food Safe 3D Printer Filaments</h2>Various thermoplastic polymers can be considered for food-safe 3D printing, and each has its benefits and limitations. For example, PETG offers good durability and moderate heat resistance but may not be dishwasher-safe, PLA is easy to print and plant-based but has poor heat tolerance and often contains non-food-safe additives, while PP has excellent chemical resistance and heat tolerance but is challenging to print. High-performance polymers like PEI and PEEK are ideal for demanding applications but need specialized printers. Furthermore, additives and colorants can compromise safety, making natural or certified filaments more appealing than others.<table><tbody><tr><td>Filament Type</td><td>Typical Nozzle Temp (°C)</td><td>Food Safety Notes</td><td>Printability</td><td>Key Properties</td><td>Common Uses</td></tr><tr><td>PLA</td><td>190–220</td><td>Base GRAS (FDA). Compliance claims exist. Additives/Colors often NOT compliant.</td><td>Easy to print, low warping.</td><td>Brittle, low temp resistance.</td><td>Cookie cutters, short-term dry food contact, molds (low temp). NOT for hot liquids/food, NOT dishwasher safe.</td></tr><tr><td>PETG</td><td>220–250</td><td>Often considered food-safe (raw). Compliance claims exist. Check additives.</td><td>Moderate difficulty, potential stringing, good bed adhesion.</td><td>Strong, durable, good chemical resistance, transparent options.</td><td>Containers (caution with long term), utensils, mechanical parts. Generally NOT dishwasher safe (may warp).</td></tr><tr><td>PP</td><td>210–230 (varies)</td><td>Often used in food containers. Compliance claims exist. Good chemical resistance.</td><td>Difficult, high warping, poor adhesion. Needs special bed prep (tape/glue).</td><td>Lightweight, flexible, fatigue resistant (hinges), chemical resistant.</td><td>Containers, living hinges, parts needing chemical resistance. Often dishwasher/microwave safe (check grade).</td></tr><tr><td>Nylon (PA11/12)</td><td>240–270+</td><td>Some grades claim compliance/biocompatibility.</td><td>Moderate to difficult, hygroscopic (needs drying), potential warping.</td><td>Strong, tough, abrasion resistant, good temp resistance.</td><td>Functional parts, gears, utensils (with coating). Check specific grade suitability.</td></tr><tr><td>PEI (ULTEM)</td><td>350–400+</td><td>FDA compliant grades exist.</td><td>Very Difficult, requires high-temp printer with heated chamber.</td><td>Very strong, rigid, high temp &amp; chemical resistance.</td><td>Demanding applications, sterilization possible. High cost.</td></tr></tbody></table><h2>Making Printed Parts Food Safe</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1748275188899-3d_printer_nozzle_closeup.jpg" style="width:100%px" class="fr-fic fr-dib" alt="nozzle" />Nozzle material determines whether a 3D printer is able to make food-safe partsEnsuring food safety in 3D printed parts requires much more than buying a food safe 3D printer filament. It also demands careful mitigation of physical, chemical, and process-related risks. Physically, FDM prints contain microscopic voids and layer lines that can trap food and moisture, encouraging bacterial growth and biofilm formation.[4] Although some cleaning methods are promising, surface porosity is a big concern, especially when the parts are designed for repeated use.Chemical risks include the migration of harmful substances from the plastic into food. These can originate from residual monomers, additives, degradation byproducts (NIAS), and even microscopic bits of printer hardware like brass nozzles that may release lead. Migration is affected by contact time, food type, and temperature.3D printer users also need to watch out for process-related risks when printing food products. Printer components—such as nozzles, extruder PTFE tubes, and lubricants—may not be food-safe and can therefore lead to contamination. Material degradation from excessive heat can release VOCs and toxic byproducts. All these risks are interrelated; porous surfaces increase chemical migration, and contaminated hardware adds unknown substances to prints.Fortunately, there are strategies for tackling all these potential issues. Mitigation can involve using certified food-safe materials, stainless steel nozzles, and dedicated clean printers. Print settings (e.g., infill density) can be adjusted to minimize gaps, while adding food-safe coatings like epoxy or silicone during post-processing can help seal surfaces. Cleaning with mild soap and water is important, but high heat and abrasives should be avoided.Achieving fully food-safe 3D printed items remains difficult, but some applications are viable with precautions, as will be shown in the section below. However, feasibility depends on usage context, material choice, processing, and hygiene practices.Recommended reading: <a href="https://www.wevolver.com/article/strongest-3d-printer-filament" target="_blank" rel="noopener noreferrer">Strongest 3D Printer Filament: Choosing Between PC, Nylon, TPU, and Others</a><h2>Uses for Food Safe 3D Printer Filament</h2><h3>✅ Suitable Applications (With Proper Precautions)</h3><table><tbody><tr><td>Application Type</td><td>Description</td><td>Precautions</td></tr><tr><td>Short-Term Contact</td><td>Cookie cutters, chocolate molds, cake toppers, stencils</td><td>Use food-safe coating, wash immediately after use, avoid prolonged contact</td></tr><tr><td>Indirect Contact</td><td>Machine components in hygienic zones (e.g., jigs, holders)</td><td>Ensure no direct contact with food, use suitable materials</td></tr><tr><td>Dry Food Handling</td><td>Scoops, funnels, spice containers (short-term use)</td><td>Prefer dry, non-acidic foods; seal surfaces; clean thoroughly</td></tr><tr><td>Mold Making for Casting</td><td>Masters for silicone molds (e.g., SLA prints for casting)</td><td>Final product must be certified food-safe; 3D print does not touch food</td></tr></tbody></table><h3>❌ Unsuitable or High-Risk Applications</h3><table><tbody><tr><td>Application Type</td><td>Risk Factors</td><td>Reason for Unsuitability</td></tr><tr><td>Long-Term Storage</td><td>Time, moisture, bacterial growth</td><td>Difficult to sanitize; chemical migration risk increases</td></tr><tr><td>Hot Food Contact</td><td>High temperatures, heat deformation</td><td>PLA, PETG deform; coatings may fail at high temp</td></tr><tr><td>Cutting Boards</td><td>Surface damage during use</td><td>Grooves trap bacteria, compromise coatings</td></tr><tr><td>Dishwasher Use</td><td>Heat, moisture, harsh detergents</td><td>Materials warp; coatings degrade</td></tr><tr><td>Medical/Infant Products</td><td>Sterility, regulatory standards</td><td>Consumer-grade 3D prints don’t meet required safety levels</td></tr></tbody></table><h2>Conclusion</h2>3D printing offers exciting possibilities for customized food-contact items, but safety remains a complex challenge. It's not enough to use “food-grade” filament—risks from porosity, contamination, and degradation must also be addressed. A truly food-safe part requires certified materials, stainless steel hardware, careful print settings, and surface sealing with certified coatings. Even then, most FDM prints are only suitable for brief, low-risk use due to difficulties in cleaning and material limitations, whereas long-term or high-heat contact is not usually advisable. Engineers must take a systems-based approach, stay current with regulations, and assess each application individually to ensure safe outcomes.<h2>Frequently Asked Questions</h2>Is PLA filament food safe?Not by default. The base PLA is GRAS, but additives and print porosity make it risky. Use natural, certified PLA and a food-safe coating. Avoid heat or long use.Can I put 3D prints in the dishwasher?Usually not. PLA and PETG warp in heat. Even stronger materials need coatings that can survive dishwashers.How do I make a print food safe?Use certified filament, stainless nozzle, dial in print settings, apply a food-safe coating, and clean thoroughly. No shortcuts.Do I need a special printer?Not always, but a clean, dedicated printer with a stainless nozzle is safer. High-temp materials need advanced printers.Are 3D printed cookie cutters safe?Safer than most uses due to their brief, low-moisture contact with food. Still, use certified filament, coat the surface, and clean right after use.<h2>References</h2>[1] U.S. Food and Drug Administration. <a href="https://www.ecfr.gov/current/title-21/chapter-I/subchapter-B/part-177" target="_blank">Indirect food additives: polymers</a>. Code of Federal Regulations, Title 21, Part 177. Silver Spring (MD): FDA; 2024.[2] European Commission. <a href="https://food.ec.europa.eu/food-safety/chemical-safety/food-contact-materials/legislation_en" target="_blank">Food contact materials legislation</a>. European Commission; 2024.[3] NSF International. <a href="https://www.nsf.org/knowledge-library/what-is-third-party-certification" target="_blank">What is third-party certification?</a> Knowledge Library [internet]. NSF International; 2020 Jun 29 [cited 2025 Apr 15].[4] Sebbar K, El Aabedy A, Ibnsouda Koraichi S, Ulag S, Gunduz O, Elabed S. <a href="https://www.mdpi.com/2079-6412/14/4/400" target="_blank">Greener Approaches to Combat Biofilm’s Antimicrobial Resistance on 3D-Printed Materials: A Systematic Review</a>. Coatings. 2024 Mar 28;14(4):400.

This article looks at materials, regulations, risks, and best practices for creating food-contact objects using food safe 3D printer filament.

Food Safe 3D Printer Filament: A Guide for Engineers

Here’s what you need to know about recycling PLA 3D printer filament and cutting back on 3D printing plastic waste.


PLA Recycling: Can PLA 3D Printer Filament be Recycled?

ABS can endure moderate temperatures before it melts

ABS is a widely used 3D printing filament with good impact resistance and flexural strength. It also exhibits moderate heat resistance, making it a go-to material for mid-temperature 3D printing applications.

3D Printing & Digital Manufacturing