Articles tagged with "3D-printing"
New tech 3D-prints durable zirconia dental crowns in just hours
Researchers at the University of Texas at Dallas have developed a groundbreaking 3D-printing technology that enables the production of permanent zirconia dental crowns in just a few hours, potentially allowing patients to receive same-day restorations. Zirconia is considered the gold standard for durable dental work, but traditional manufacturing methods, such as milling, limit design complexity and risk micro-cracking. Existing 3D-printed crowns use ceramic resins that lack zirconia’s strength. The key innovation lies in drastically reducing the debinding process—from 20-100 hours to under 30 minutes—by using porous graphite felt, enhanced heat transfer, and a vacuum system that safely removes gas during resin burnout, preventing cracks and fractures. This advancement not only accelerates the production timeline but also offers stronger, more customizable dental restorations compared to resin alternatives and milled zirconia. The technology promises to lower waste and costs while improving patient experience by enabling dentists to provide permanent crowns, bridges, and veneers chair-side in a
materials3D-printingzirconiadental-technologymanufacturing-innovationrapid-prototypingdental-restorationsVideo: Robotic hand with 16 joints perfectly opens soda can like humans
TetherIA, a California-based company, has developed the Aero Hand Open, an open-source, tendon-driven robotic hand designed to tackle the challenge of dexterous manipulation in robotics. Featuring 16 joints, the robotic hand can perform precise tasks such as grasping small objects, picking up an iPhone, and even opening a soda can with human-like dexterity. Its underactuated design uses cables running through the fingers instead of individual motors for each joint, allowing the hand to conform naturally to various object shapes. This compliance enhances its ability to handle everyday objects with precision and adaptability. The Aero Hand Open emphasizes simplicity, affordability, and accessibility. It is fully 3D-printable, lightweight, and integrates open-source ESP32-based firmware and ROS2-compatible control software, making it suitable for research and educational use. Priced at $314 for a complete kit, it offers a modular platform that can be assembled with standard equipment and off-the-shelf components. Additionally, the system includes a
robotroboticsrobotic-handdexterous-manipulationopen-source-roboticstendon-driven-actuation3D-printingMini 3D printer could enable on-site tissue repair inside human body
Researchers at the University of Stuttgart, led by Andrea Toulouse, have developed a miniaturized 3D printer capable of creating living tissue directly inside the human body. This innovative device uses a glass optical fiber thinner than a pencil lead, equipped with a tiny 3D-printed lens no larger than a grain of salt, to focus laser light and cure bio-inks layer by layer with micrometer precision. This approach aims to overcome the limitations of traditional bioprinting, which requires implanting pre-grown tissues and relies on large, less precise printers unsuitable for in-body use. The project, supported by a $2 million grant from the Carl Zeiss Foundation, combines photonics, biotechnology, and precision engineering to enable endoscopic 3D printing of complex tissue structures at the cellular scale. Collaborating with experts in biomaterials, the team is also developing biodegradable bio-inks compatible with living cells to ensure safe integration into the body. By integrating their research into the Bionic Intelligence Tüb
materials3D-printingbio-inksmicro-opticsregenerative-medicinetissue-engineeringphotonicsNew software helps build 3D objects with smooth material transitions
OpenVCAD is a new open-source software tool developed at the University of Colorado Boulder that revolutionizes multi-material 3D design by enabling engineers to create objects with smooth material gradients through code-driven precision. Unlike traditional CAD tools that define only an object’s outer boundaries and assume a single interior material, OpenVCAD allows users to assign complex mathematical functions to represent spatially varying materials within a 3D object. This capability simplifies the design of gradient objects—such as shoe soles transitioning from firm to soft—by letting users update designs through small code changes rather than redrawing entire models. Created in the Matter Assembly Computation Lab under Assistant Professor Robert MacCurdy and developed by PhD student Charles Wade, OpenVCAD supports multi-material printing with up to five materials simultaneously and has demonstrated versatility across various 3D printers. Its applications extend beyond academia to fields like medical modeling, soft robotics, and structural engineering, where it can help create lifelike anatomical models, flexible robotic actuators, and
3D-printingmulti-material-designadditive-manufacturingCAD-softwarematerials-engineeringcomputational-designgradient-materialsSwiss scientists' new 3D printing method delivers ultra-strong materials
Researchers at EPFL have developed a novel 3D printing method that creates ultra-strong metal and ceramic materials by growing them inside a water-based hydrogel scaffold. Unlike traditional approaches that harden resin pre-infused with metal precursors using light, this technique first prints a simple hydrogel structure, which is then infused repeatedly with metal salts and chemically converted into metal-containing nanoparticles. This post-printing material infusion allows for high metal concentrations and results in dense, intricate architectures with significantly improved mechanical properties. The new materials can withstand pressures up to 20 times greater than those produced by previous methods while exhibiting only about 20% shrinkage compared to the typical 60-90%. The team demonstrated the method’s versatility by fabricating complex gyroid lattice structures from iron, silver, and copper, which are strong yet lightweight. This approach is promising for advanced applications requiring complex 3D architectures that combine strength and low weight, such as sensors, biomedical devices, and energy conversion or storage technologies. The
3D-printingadvanced-materialsadditive-manufacturingceramicsmetalsenergy-technologiesbiomedical-devicesMIT's high strength aluminum alloy can withstand high temperature
Researchers at MIT have developed a novel printable aluminum alloy that is reportedly five times stronger than traditionally manufactured aluminum and can withstand high temperatures. Using a machine learning (ML)-based approach combined with simulations, the team evaluated only 40 possible material compositions—significantly fewer than the over one million combinations typically required—to identify an optimal mix of aluminum and other elements. This alloy exhibits a high volume fraction of small precipitates, which contribute to its enhanced strength, surpassing previous benchmarks including the wrought Al 7075 alloy. The new alloy, produced via 3D printing rather than conventional casting, benefits from rapid solidification that prevents precipitate growth, resulting in superior mechanical properties. After aging at 400 °C for eight hours, the alloy achieves a tensile strength of 395 MPa at room temperature, about 50% stronger than the best-known printable aluminum alloys. The researchers envision applications in lightweight, temperature-resistant components such as jet engine fan blades—traditionally made from heavier and more expensive
materialsaluminum-alloy3D-printinghigh-strength-materialsmachine-learningadditive-manufacturinglightweight-materialsPhotos: World's first hollow concrete guitar is surprisingly playable
Rob Scallon and Mike from Modustrial Maker have successfully created the world’s first semi-hollow body concrete guitar, modeled after a Gibson ES335. Unlike earlier concrete guitars that were heavy and solid, this instrument features 3/8-inch thick walls and weighs under 20 pounds, making it surprisingly playable. The build showcased exceptional precision, achieving perfect intonation without any post-build adjustments. The guitar’s body was engineered to prevent cracking by using a self-leveling concrete mix with plasticizers, reinforced with glass fiber scrim, PVA fibers, and embedded wood components. CNC-machined and 3D-printed molds ensured accurate neck alignment, while careful wet sanding preserved the integrity of the thin concrete walls. The construction process was challenging due to the quick curing time of concrete and the material’s properties, requiring meticulous machining and finishing. The project cost about $400, including hardware, electronics, and a Schecter neck. The finished guitar functions well as a musical instrument, with no fret
materialsconcreteguitar3D-printingfabricationengineeringcomposite-materialsAirbus backs 3D-printed heat exchanger to cool hydrogen-electric jets
Airbus is advancing its hydrogen-electric aviation efforts through collaboration with Conflux Technology, which is developing a next-generation 3D-printed heat exchanger critical for thermal management in megawatt-class hydrogen fuel cell systems. This lightweight, high-performance component, created using additive manufacturing and validated with Computational Fluid Dynamics (CFD) modeling, is designed to regulate the substantial heat generated by hydrogen fuel cells, ensuring safe and efficient operation of Airbus’ ZEROe hydrogen-electric propulsion systems. The ZEROe program aims to produce the first zero-emission commercial aircraft powered by hydrogen fuel cells, targeting entry into service by 2035, with water vapor as the only emission. Despite technological progress, including successful testing of a 1.2-megawatt fuel cell engine and advancements in liquid hydrogen storage, the ZEROe program has faced delays, pushing the timeline back by 5 to 10 years and reducing its budget by 25%. These setbacks stem from the complexity of developing the propulsion technology and establishing a global
energyhydrogen-fuel-cells3D-printingaerospacethermal-managementadditive-manufacturingsustainable-aviationRussia turns Chinese 'golf carts' into remote-controlled war robots
Russian forces have repurposed Chinese-made Desertcross 1000-3 all-terrain vehicles (ATVs), originally designed as recreational utility vehicles, into remote-controlled battlefield robots. This adaptation was carried out by the 36th Guards Combined Arms Army of Vostok and reported in early October 2024 during operations in Ukraine. The modified vehicles are used primarily to lay up to five kilometers of fiber-optic communication cable remotely, reducing the exposure of Russian signal troops to enemy fire. These conversions utilize commercially available electronics and 3D-printed parts, allowing operators to control the vehicles from a safe distance, thereby minimizing casualties in high-risk frontline zones. Beyond communication roles, the Desertcross ATVs have been adapted for logistical support and direct combat, with some fitted with various machine guns and grenade launchers, as well as anti-drone defenses like nets or cages. While these vehicles offer a cost-effective and flexible solution amid Russia’s operational challenges, they remain lightly armored and vulnerable to destruction by
robotremote-controlbattlefield-robotsmilitary-technologyfiber-optic-cable-laying3D-printingunmanned-vehiclesSpider-like robot can 3D print homes in a day to fight housing crunch
Australia has developed an advanced spider-like robot named Charlotte, designed to address the housing crisis by 3D printing low-cost, low-carbon homes rapidly. Created through a collaboration between Crest Robotics and Earthbuilt Technology, Charlotte can autonomously print a 200-square-metre house within 24 hours by transforming readily available materials such as sand, earth, and crushed brick into structural walls. The robot employs a sustainable Earthbagging-like technique, compacting these materials in fabric layers to build durable structures efficiently, offering a scalable solution to the slow and costly traditional construction methods. Beyond Earth, Charlotte is engineered for lunar construction, supporting NASA and other space agencies' ambitions to establish permanent bases on the Moon. Its lightweight, foldable hexapod design makes it highly portable for space travel, unlike bulky traditional 3D printers, and allows it to extrude and compact lunar soil to build habitats such as domed shelters. This innovation positions Charlotte within a competitive global effort alongside companies like ICON and AI SpaceFactory
robotics3D-printingconstruction-technologylunar-habitatsautonomous-robotssustainable-buildingspace-exploration3D-printed hypercar smashes 5 track records in as many days
Czinger’s 3D-printed 21C hypercar achieved a remarkable feat by breaking five official production lap records on five consecutive days during a 1,000-mile campaign across California, known as the California Gold Rush campaign. The hypercar set new lap times at Thunderhill Raceway Park, Sonoma Raceway, Laguna Seca, Willow Springs, and The Thermal Club, collectively shaving 16.26 seconds off previous benchmarks. Each record was verified by RaceLogic’s VBox GNSS system and independent witnesses, underscoring the car’s exceptional performance and endurance. Powered by a twin-turbocharged 2.9-liter V8 engine combined with a 4.4-kWh battery pack, the 21C produces 1,350 horsepower and reaches a top speed of 253 mph. Notably, the car used the same standard configuration for all runs without any hidden upgrades, demonstrating the durability and capability of its 3D-printed components under varied track conditions and temperatures. Driver
3D-printinghypercarautomotive-materialsenergy-storageelectric-hybridhigh-performance-engineeringadvanced-manufacturingUS pursues low-cost hypersonic missile with 4,000-pound thrust engine
The U.S. Air Force is developing an experimental hypersonic missile called "Angry Tortoise," aimed at demonstrating a lower-cost approach to hypersonic weaponry and ballistic threat simulation. Central to the project is the Draper rocket motor, a 4,000-pound-thrust liquid-fueled engine using a hydrogen peroxide–kerosene mix that can be stored at room temperature for extended periods, enhancing tactical readiness. About 60 percent of the motor's parts are 3D printed, enabling significant cost reductions compared to current hypersonic propulsion systems. The program leverages components from the existing Economical Target-2 (ET-2) rocket to further cut costs while improving performance. The first test flight is scheduled for December 2025 at White Sands Missile Range, initially targeting speeds near Mach 2, with potential to reach Mach 4 or Mach 5 in future iterations. The project is currently a science and technology demonstration rather than an immediate weapons deployment, with
energyhypersonic-missile3D-printingadditive-manufacturingrocket-propulsionmilitary-technologyaerospace-materialsKorean researchers create bone-healing gun, offers faster treatment
Korean researchers at Sungkyunkwan University have developed a handheld “bone-healing gun,” a 3D-printing device that extrudes biodegradable polymer scaffolds directly onto fractured bones to accelerate healing. Unlike traditional metal grafts and titanium implants, which are costly and difficult to customize, this device uses a biocompatible filament made from a blend of polycaprolactone and hydroxyapatite. This material melts at a safe 60 °C, allowing it to bond securely to bone tissue without damaging surrounding areas, while providing strength comparable to natural bone and gradually degrading as new bone grows. Early animal trials on rabbits with femur fractures showed that the bone-healing gun significantly sped up recovery compared to standard bone cement. However, the slow degradation rate of the scaffold material limited full fracture restoration, indicating the need for further improvements before human trials. The researchers aim to enhance the material’s biodegradation speed and incorporate antibiotics to release infection-fighting drugs during healing. Additional challenges include ensuring
materialsbiodegradable-polymers3D-printingbone-healingbiomedical-engineeringmedical-devicespolymer-scaffoldsRobotic exoskeleton gives YouTuber 63% aim boost, 17ms latency
YouTuber Nick Zetta, known as Basically Homeless, developed a robotic exoskeleton aimed at enhancing aiming performance in the Aimlabs training program. Combining Nvidia Jetson hardware with a YOLO-powered AI vision system, motors, and 3D-printed components, the device physically guides his wrist and fingers to improve target acquisition. Initial tests showed a 20% accuracy drop as Zetta adapted to the system, but after hardware optimizations—such as reducing latency from 50ms to 17ms and increasing motor strength—he achieved a 63% boost in his Aimlabs score, propelling him to second place on the global leaderboard. The exoskeleton attaches to the forearm using 3D-printed hinges, with Kevlar lines and gimbal motors controlling wrist movements and solenoids managing finger clicks. A high-speed camera feeds real-time target data to the AI, which directs the motors to adjust hand positioning, effectively acting as a physical aimbot. Unlike
roboticsrobotic-exoskeletonAI-visioncomputer-visionNvidia-Jetson3D-printingassistive-technology3D printing creates human tissue with stretch and blood-like fluids
Researchers at the University of Minnesota Twin Cities have developed an advanced 3D printing technique that produces human tissue models with realistic mechanical properties and blood-like fluids, significantly improving the fidelity of surgical training tools. By controlling microscopic patterns within the printed material, the team achieved tissues that mimic the strength and stretchiness of real organs. Additionally, they incorporated sealed microcapsules containing blood-like liquids to enhance the models’ realism without compromising the printing process. Surgeons who tested these models rated them higher than conventional replicas in tactile feedback and cutting response, suggesting that such improvements could lead to safer and more effective surgical practice. The research team, including experts from mechanical and biomedical engineering and collaborators from the University of Washington, also developed a mathematical formula to predict tissue behavior under stress. While scaling the technology for widespread use will take time, the method shows strong potential for specialized, low-volume training scenarios. Future research aims to replicate various organ shapes and functions, develop bionic organs, and integrate materials responsive to advanced surgical tools
3D-printingbiomaterialssurgical-trainingtissue-engineeringmedical-devicessynthetic-organsbiomedical-engineeringDeLorean recreated with drones, lifts off like 'Back to the Future'
Designer Brian Brocken has successfully recreated a full-scale flying DeLorean from the movie Back to the Future, fulfilling a childhood dream by combining detailed replica craftsmanship with advanced drone technology. The car’s body is constructed from lightweight EPS foam reinforced with fiberglass to maintain the iconic styling without excess weight. Using CAD software and CNC-cut foam slices, Brocken precisely assembled the hollow shell, while a custom carbon-fiber tubular frame provides the necessary strength and rigidity for flight, reducing weight to about 2 kg (4.4 lbs) and addressing structural flex issues encountered with earlier aluminum frames. The replica features functional elements true to the film, including retractable, rotating wheels 3D printed from PLA that enable both ground steering and in-flight folding, as well as gullwing doors with hidden 3D-printed hinges that open automatically. Flight stability was enhanced by adding thrust vector control fins under the four powerful drone motors, each paired with 30-inch propellers producing up to 13.5 kg (
roboticsdronescarbon-fiberlightweight-materials3D-printingCAD-designUAV-engineeringArgonne studies 3D-printed steels for next-gen nuclear reactors
Researchers at the US Department of Energy’s Argonne National Laboratory have conducted studies on 3D-printed stainless steels to support the development of next-generation nuclear reactor components. Using laser powder bed fusion (LPBF), an additive manufacturing technique, they produced samples of two key alloys: 316H, a conventional stainless steel used in reactors, and Alloy 709 (A709), a newer alloy designed for advanced nuclear applications. The LPBF process creates unique microstructural features due to rapid heating and cooling, including numerous dislocations that can both strengthen the steel and increase its susceptibility to fracture. Heat treatments are applied to relieve stress by allowing atomic rearrangement, but some dislocations may be retained to enhance performance. The studies revealed significant differences between 3D-printed and conventionally wrought steels, particularly in how the printed materials respond to heat treatments. For 316H, experiments using advanced microscopy and in situ X-ray diffraction showed that nano oxides—common defects in 3D-printed
materials3D-printingadditive-manufacturingstainless-steelnuclear-reactorsheat-treatmentlaser-powder-bed-fusion14-ingredient meal cooked by lasers sets new record in 3D-printed food
A research team led by Jonathan David Blutinger, PhD, has achieved a significant breakthrough in 3D-printed food by creating a 14-ingredient, three-course meal using multi-wavelength laser cooking. This novel technique employs multiple laser wavelengths to precisely control the texture of printed foods during the printing process, addressing one of the biggest challenges in 3D food printing—replicating the texture of traditionally cooked meals. Unlike conventional ovens or stovetops that apply heat unevenly, lasers deliver targeted energy bursts at shallow depths, enabling fine-tuning of elasticity, firmness, and chewiness across different layers of the food. The team tested blue, near-infrared, and mid-infrared lasers on Graham cracker dough and found that laser cooking could achieve peak elasticity at mid-strain levels, surpassing the texture quality of oven-baked samples. By modulating laser exposure frequency, they engineered the internal structure of the dough with precision. This advancement allowed them to produce the most complex
materials3D-printinglaser-cookingfood-technologymulti-wavelength-lasertexture-engineeringadditive-manufacturing3D printable bio-glass scaffold shows promise as bone replacement
Researchers in China have developed a novel 3D printable bio-active glass scaffold that shows promise as a bone replacement material. Unlike traditional glass, which is brittle and difficult to shape safely for medical use, this new bio-glass combines silica particles with calcium and phosphate ions to form a printable gel. This gel can be hardened at a relatively low temperature (1,300°F), avoiding the toxic plasticizers and extreme heat (above 2,000°F) typically required in glass 3D printing. In animal tests involving rabbit skull repair, the bio-glass scaffold supported sustained bone cell growth over eight weeks, outperforming plain silica glass and nearly matching a leading commercial dental bone substitute in durability. The key innovation lies in the “green” inorganic 3D printing strategy, which uses self-healing colloidal gels made from silica-based nanospheres that attract each other electrostatically. This method eliminates the need for organic additives, reduces costs, preserves bioactivity, and enhances printability and shape
materials3D-printingbio-glassbone-replacementbiomedical-engineeringnanomaterialsadditive-manufacturingFirst 3D-printed ion traps hit 98% fidelity in quantum operations
Scientists from Lawrence Livermore National Laboratory (LLNL), in collaboration with UC Berkeley, UC Riverside, and UC Santa Barbara, have developed miniaturized quadrupole ion traps using high-resolution 3D printing, achieving quantum gate fidelities as high as 98%. These 3D-printed ion traps combine the stability advantages of traditional bulky 3D traps with the scalability of planar traps, overcoming a longstanding tradeoff in quantum computing hardware. The traps confine calcium ions at competitive frequencies and error rates, enabling stable ion manipulation, including two-ion position exchanges lasting minutes and high-fidelity two-qubit entangling gates. The use of ultrahigh-resolution two-photon polymerization printing allows rapid prototyping—printing full traps in about 14 hours or just electrodes in 30 minutes—significantly accelerating design iterations and enabling complex hybrid planar-3D geometries. This expanded design flexibility opens new avenues for optimizing and miniaturizing ion traps. The team plans to further
3D-printingion-trapsquantum-computingmaterials-engineeringminiaturizationquantum-informationadvanced-manufacturingMagnet-controlled soft metamaterial resists acid and holds shape
Researchers at Rice University have developed a novel soft metamaterial that can rapidly change size and shape under remote magnetic control, combining exceptional flexibility with high strength and stability. Unlike traditional materials, this metamaterial’s properties arise from its engineered geometry rather than its chemical composition. It features “programmed multistability” enabled by trapezoidal supports and reinforced beams that lock the structure into new shapes even after external forces are removed. The material withstands compressive loads over ten times its weight and remains functional under extreme temperatures and corrosive conditions, such as those found in the human stomach. Constructed using 3D-printed molds, the metamaterial’s microarchitecture allows it to switch between open and closed states with magnetic triggers, retaining its shape afterward, effectively giving it a form of memory. Larger structures made by linking unit cells can perform complex motions like peristaltic waves, enabling controlled movement or fluid delivery. This soft, adaptable design aims to reduce risks associated with rigid implantable devices, such
materialssoft-metamaterials3D-printingmedical-devicesremote-controlprogrammable-materialsmicroarchitectureCoral-inspired New 3D printed fuel cell could power lighter jets
Researchers at the Technical University of Denmark have developed a novel, lightweight fuel cell called the Monolithic Gyroidal Solid Oxide Cell (The Monolith), inspired by coral structures and manufactured using 3D printing. This fully ceramic fuel cell eliminates heavy metal components that typically constitute over 75% of conventional fuel cells' weight, resulting in a device that produces over one watt per gram—an unprecedented power-to-weight ratio suitable for aerospace applications. Its gyroid-based architecture maximizes surface area, enhances gas flow, improves heat distribution, and increases mechanical stability. The manufacturing process is simplified to just five steps, avoiding fragile seals and multiple materials, which enhances durability and longevity. The Monolith fuel cell demonstrates remarkable resilience, withstanding extreme temperature fluctuations of 100°C and repeated switching between power-generating and power-storing modes without structural failure. It also produces hydrogen at nearly ten times the rate of standard models during electrolysis. These features make it a promising technology for aerospace and space missions, where
energyfuel-cells3D-printinghydrogen-productionaerospace-technologyceramic-materialsrenewable-energyDivergent raises $290M to expand production of specialized military parts
Divergent Technologies, an advanced manufacturing company specializing in military components, has raised $290 million in a funding round that values the company at $2.3 billion. The capital infusion, which includes $40 million in debt, will be used to expand Divergent’s manufacturing facilities in Los Angeles and to initiate construction of a new factory in Oklahoma next year. The company’s specialized 3D printers produce up to 600 parts, with metal missile airframes being a core product. Divergent’s clientele includes major defense contractors such as Lockheed Martin, RTX, and General Dynamics. This funding round highlights strong investor interest in startups that enhance domestic manufacturing capabilities amid increasing demand for advanced weapons systems, which is putting pressure on traditional supply chains. CEO Lukas Czinger emphasized the importance of missile parts production as a key business focus for Divergent.
materialsadvanced-manufacturing3D-printingmilitary-partsdefense-technologymetal-componentsproduction-expansion3D printed placenta models pave way for safer pregnancy drug testing
Researchers at the University of Technology Sydney (UTS) have achieved a world-first by 3D bioprinting miniature placentas, offering a novel and safer method to study early pregnancy complications. Traditional challenges in pregnancy research stem from the difficulty and risks of obtaining first-trimester placental tissue and the inadequacy of animal and cell models to replicate human placental function accurately. The UTS team combined trophoblast cells—unique to the placenta—with a synthetic gel, printing them in precise droplets to create organoids that closely mimic early human placental tissue. These bioprinted organoids developed differently from those grown in animal-derived gels, highlighting how the growth environment influences placental cell maturation. This advancement enables safer investigation into pregnancy disorders such as preeclampsia, a condition affecting 5–8% of pregnancies and linked to placental dysfunction. The researchers demonstrated the model’s utility by exposing the organoids to inflammatory molecules associated with preeclampsia and testing potential treatments,
materials3D-printingbioprintingorganoidsmedical-researchtissue-engineeringpregnancy-complicationsWhat did dinosaurs sound like? 3D-printed skulls reveal their lost voices
The article explores the innovative work of Courtney Brown, an associate professor at Southern Methodist University, who has spent over a decade combining paleontology, music, computer science, and 3D printing to recreate the possible sounds of dinosaurs. Unlike the iconic roars popularized by media, the true voices of dinosaurs remain unknown due to the absence of vocal fossil records. Brown’s project, the Dinosaur Choir, focuses on hadrosaurs like Corythosaurus, which had elaborate nasal crests believed to function as resonance chambers for producing deep calls. Using CT scans of dinosaur skulls, Brown and her team 3D-printed these structures and integrated mechanical larynxes to generate sounds that mimic how these dinosaurs might have vocalized, producing haunting and varied tones. Further advancements came post-pandemic through collaboration with design professor Cezary Gajewski, who helped redesign the instruments by replacing mouthpieces with sensors that detect vibrations from a player’s voice or subtle movements. This system digitally processes these
3D-printingpaleontologymaterials-scienceacoustic-modelingdinosaur-reconstruction3D-printed-materialsbio-inspired-designBoeing 3D-prints solar arrays, cutting satellite build time by 50%
Boeing has introduced 3D-printed solar array substrates that significantly reduce satellite production time by up to 50%, cutting composite build times by as much as six months on typical solar array wing programs. This innovation integrates features such as harness paths and attachment points directly into a single rigid panel, eliminating numerous separate parts and complex bonding steps. The arrays, which incorporate Spectrolab’s high-efficiency solar cells and are set to fly on small satellites built by Millennium Space Systems, are currently undergoing Boeing’s qualification process with market availability targeted for 2026. The new additive manufacturing approach enables parallel production processes, allowing solar arrays to be assembled concurrently with solar cell fabrication, thereby reducing lead times and supporting higher-rate production. Boeing’s use of robot-assisted assembly and automated inspection further enhances consistency and speed. This scalable technology is designed for a range of spacecraft, from small satellites to larger platforms like Boeing’s 702-class spacecraft. Boeing has already integrated over 150,000 3D-printed
energysolar-energy3D-printingaerospacesatellite-technologyadditive-manufacturingBoeingResearchers Create 3D-Printed Artificial Skin That Allows Blood Circulation
Swedish researchers have developed innovative 3D bioprinting techniques to create thick, vascularized artificial skin that could significantly improve treatment for severe burns and trauma. Traditional skin grafts transplant only the epidermis and fail to regenerate the dermis—the deeper skin layer containing blood vessels and nerves—resulting in scarring and loss of full skin function. The new methods aim to overcome this by producing skin that includes living cells and a network of blood vessels, essential for delivering oxygen and nutrients to sustain tissue viability. The team led by Johan Junker at Linköping University created a bio-ink called “μInk,” which embeds fibroblasts (cells that generate dermal components like collagen) within a gel matrix, allowing 3D printing of dense, cell-rich skin structures. In mouse transplantation experiments, these constructs supported cell growth, collagen secretion, and new blood vessel formation, indicating potential for long-term tissue integration. Complementing this, the researchers developed the REFRESH technology, which uses
materials3D-printingbioprintingartificial-skintissue-engineeringbiomedical-materialsregenerative-medicineNew 3D print method reduces plastic use without losing strength
MIT researchers from CSAIL and the Hasso Plattner Institute have developed SustainaPrint, a hybrid 3D printing system that significantly reduces plastic waste without compromising structural strength. The method uses simulations to identify stress-prone zones in a 3D model and selectively reinforces these areas with high-performance plastics, while printing the rest of the object with biodegradable or recycled filament. This targeted reinforcement approach cuts down plastic use and maintains durability, addressing the common trade-off between eco-friendliness and strength in 3D printing materials. In tests using Polymaker’s eco-friendly PolyTerra PLA and Ultimaker’s stronger PLA, SustainaPrint required only 20% reinforcement to regain up to 70% of the strength of fully reinforced prints. In some cases, the hybrid prints matched or even outperformed fully strong prints, demonstrating that strategic material mixing can enhance performance depending on geometry and load conditions. The system includes an open-source software interface for uploading models and running stress simulations, along with
3D-printingsustainable-materialsplastic-waste-reductionmaterial-sciencestructural-engineeringeco-friendly-manufacturingMIT-research3D-printed scaffolds guide stem cells to repair spinal cord injury
A research team at the University of Minnesota Twin Cities has developed a novel approach to spinal cord injury repair by combining 3D printing, stem cell biology, and regenerative medicine. They created a 3D-printed organoid scaffold containing microscopic channels filled with spinal neural progenitor cells (sNPCs) derived from human adult stem cells. These channels guide the growth of the stem cells, promoting the formation of new nerve fibers that can bypass damaged spinal cord areas. When implanted into rats with completely severed spinal cords, the scaffolds supported the development of neurons that extended nerve fibers in both directions, integrating with existing spinal tissue and leading to significant functional recovery. The study demonstrates that the scaffold not only enhances cell survival but also enables reconnection across severe spinal injuries, marking a promising advance in regenerative medicine for paralysis. The researchers plan to scale up and refine the technology for clinical trials, aiming to eventually restore mobility and independence in people with spinal cord injuries. This interdisciplinary project involved experts in neurosurgery
materials3D-printingregenerative-medicinestem-cellsspinal-cord-injurybiomedical-engineeringtissue-engineeringStudents build aerospace 3D printer that fuses two metals at once
A team of Swiss bachelor students at ETH Zurich has developed an innovative 3D metal printer, named RAPTURE, that significantly advances aerospace manufacturing by enabling high-speed, multi-material printing. Unlike traditional 3D printers that operate in a stop-start manner, this prototype uses a rotating laser powder bed fusion (LPBF) system to continuously deposit and fuse metal powders. This design allows the simultaneous fusion of two different metals—such as a copper core with a nickel-alloy exterior—in a single seamless step, which is particularly suited for producing complex aerospace components like rocket nozzles and turbine parts with large diameters and thin walls. The rotating platform reduces production time by over two-thirds compared to conventional methods. The RAPTURE machine also incorporates a novel gas flow system that directs inert gas across the fusion zone to prevent oxidation and continuously removes by-products like soot and spatter, resulting in cleaner builds and higher part quality. This feature was found critical to the success of the printing process. Initially created to support
materials3D-printingaerospace-manufacturingmetal-fusionmulti-material-printinglaser-powder-bed-fusionpropulsion-components3D-printed auxetic sensors promise leap in wearable electronics
A research team from Seoul National University of Science and Technology, led by Mingyu Kang and Dr. Soonjae Pyo, has developed a novel 3D-printed tactile sensor platform based on auxetic mechanical metamaterials (AMMs). These materials exhibit a negative Poisson’s ratio, meaning they contract inward under compression, which concentrates strain and enhances sensitivity. Using digital light processing (DLP)-based 3D printing, the team fabricated cubic lattice structures with spherical voids that improve sensor performance by increasing sensitivity, maintaining stability, and minimizing crosstalk. The sensors operate in capacitive and piezoresistive modes, with the latter utilizing a carbon nanotube coating to detect resistance changes under load. The researchers demonstrated the technology’s potential through applications such as tactile arrays for spatial pressure mapping and wearable smart insoles capable of monitoring gait patterns and detecting pronation types. Unlike conventional porous structures, the auxetic design prevents lateral expansion, making the sensors more wearable and less prone to
3D-printingauxetic-sensorswearable-electronicstactile-sensorsroboticsmechanical-metamaterialshealth-monitoringUS' 3D-printed hybrid rocket engine system passes first flight test
Firehawk Aerospace, a Texas-based company, has successfully completed the first flight test of its 3D-printed hybrid rocket engine system, called the GMLRS-class Firehawk Analog (GFA), under a Phase III SBIR contract with the U.S. Army Applications Laboratory (AAL). The test demonstrated the system’s directional stability and thrust performance, achieving a vertical ascent exceeding 18,000 feet and breaking the speed of sound. This milestone highlights the advantages of hybrid propulsion combined with advanced additive manufacturing, including adaptability, affordability, and rapid production capabilities. The GFA test is the initial flight demonstration in a series under the AAL contract, with upcoming tests planned for Javelin-class and Stinger-class analogs designed as drop-in replacements for existing solid rocket motors in Department of Defense weapon systems. Firehawk emphasizes that their approach drastically reduces production cycles from weeks to hours and supports mobile manufacturing, enhancing force sustainment and ensuring a resilient, U.S.-controlled supply chain for critical energet
energyrocket-engineshybrid-propulsionadditive-manufacturingaerospace-technologydefense-technology3D-printingWorld’s first cervical spine surgery using 3D-printed custom implant
In July 2025, UC San Diego Health performed the world’s first anterior cervical spine surgery using a fully personalized 3D-printed titanium implant, marking a significant advancement in spinal care. Led by neurosurgeon Dr. Joseph Osorio, the procedure utilized advanced imaging, AI-assisted planning, and 3D printing technology to create an implant precisely tailored to the patient’s unique spinal anatomy. This personalized approach contrasts with traditional one-size-fits-all implants, which can compromise spinal alignment, movement, and healing. The custom implant offers benefits such as improved structural support, more accurate spinal alignment, potentially shorter recovery times, preservation of healthy anatomy, reduced complication rates, and a lower chance of repeat surgeries. This innovation represents a fundamental shift toward personalized medicine in spine surgery, with promising implications for treating conditions like spinal stenosis, degenerative disc disease, and spinal deformities. UC San Diego’s neurosurgery program, recognized nationally for its leadership and innovation, views this milestone as the start of
3D-printingtitanium-implantspersonalized-medicineAI-assisted-surgerymedical-materialsspinal-surgery-innovationcustom-implants3D-printed superconductors set new record in magnetic strength
Cornell researchers have developed a novel one-step 3D printing method to fabricate superconductors with record-setting magnetic performance. Using an ink composed of copolymers and inorganic nanoparticles that self-assemble during printing, followed by heat treatment, the team creates porous crystalline superconductors structured at atomic, mesoscopic, and macroscopic scales. This streamlined “one-pot” process bypasses traditional multi-step fabrication methods, enabling complex 3D shapes such as coils and helices while enhancing material properties through mesoscale confinement. A key achievement of this work is the printing of niobium nitride superconductors exhibiting an upper critical magnetic field of 40–50 Tesla—the highest confinement-induced value reported for this compound—crucial for applications like MRI magnets. The researchers established a direct correlation between polymer molar mass and superconductor performance, providing a design map for tuning properties. Graduate students and faculty from materials science and physics contributed to overcoming chemical and engineering challenges. Supported by the National Science Foundation and
3D-printingsuperconductorsmaterials-sciencenanotechnologyquantum-materialscopolymersmagnetic-strengthAustralia’s first 3D-printed two-storey house built in just 18 hours
Australia’s first fully 3D-printed two-storey concrete home has been completed in Tapping, Perth by Contec Australia, marking a significant advancement in construction technology. The structural walls of the house were printed on-site in just 18 hours using a high-strength concrete mix that is three times stronger than standard brick. This innovative material is cyclone-rated, fire-resistant, termite-proof, and thermally efficient. The entire build, including roofing, wiring, and interior finishes, took five months, combining rapid robotic construction for the shell with traditional craftsmanship for the finishing work. The house features modern, open-plan interiors with three bedrooms, two bathrooms, a garage, and a balcony, demonstrating that 3D-printed homes can be both stylish and livable. Large windows and sliding doors enhance natural light and indoor-outdoor flow. Importantly, Contec Australia reports that the project achieved a 22% cost saving compared to conventional masonry builds, due to faster wall construction, reduced material use,
robot3D-printingconstruction-technologyconcrete-materialsrobotic-constructionbuilding-automationsustainable-building-materials1984 Macintosh reborn with 3D-printed case, classic Apple logo
Quinn Nelson of Snazzy Labs has created a modern homage to the 1984 Apple Macintosh by designing a fully 3D-printed case that replicates the original beige computer’s iconic silhouette and rainbow Apple logo. Inside the case, a Raspberry Pi 3B+ powers an emulated classic Mac OS displayed on a 10.5-inch IPS screen that maintains the original 3:2 aspect ratio but offers higher resolution and more usable space. The build integrates vintage Apple Desktop Bus peripherals via a BMOW Wombat adapter, allowing authentic keyboards and mice to connect seamlessly, blending retro hardware with modern technology. The project showcases advanced maker techniques, including color-matched filament printing, a custom 3D-printed tray combining rigid and flexible materials to secure the Raspberry Pi, and a separately printed and finely finished rainbow Apple logo. A playful design element is the corkboard base on the underside of the case, adding practical everyday use to the retro-inspired machine. To foster community engagement and
3D-printingRaspberry-Piretro-computingmaterials-engineeringDIY-electronicscomputer-hardwarefabrication-techniquesAustrian hook-and-loop fastener to cut building repair costs
Scientists at Graz University of Technology (TU Graz) in Austria have developed an innovative hook-and-loop fastening system designed to reduce construction waste and facilitate easier building repairs and adaptations. Inspired by Velcro, this 3D-printed fastener incorporates mushroom-shaped hooks directly into building components such as concrete, wood, or paper-based materials, enabling secure yet reversible connections. This allows structural elements like floors, interior walls, and installations to be swapped or upgraded without demolition, significantly extending a building’s service life and reducing material consumption. The fastener has demonstrated tensile strength comparable to industrial fasteners in laboratory tests, with future production methods like injection molding or stamped metal expected to enhance performance further. Primarily intended for indoor use on non-load-bearing walls and components housing wiring or plumbing, the system supports more sustainable construction practices by enabling selective replacement of worn or outdated parts. Complementing this, the ReCon project team also developed a digital tagging system using embedded RFID chips and QR codes to track material composition and installation data
materialsconstruction-technologysustainable-building3D-printingfastenersbuilding-repairconstruction-waste-reductionStronger next-gen 3D-printed titanium alloy developed for aerospace use
Engineers at the Royal Melbourne Institute of Technology (RMIT) have developed a new 3D-printed titanium alloy that is about one-third cheaper and stronger than the current industry standard, such as Ti-6Al-4V. This cost reduction is achieved by replacing the expensive element vanadium with more accessible, lower-cost materials. The new alloy also overcomes a common issue in 3D-printed metals by avoiding the formation of columnar microstructures, resulting in a uniform grain structure that enhances both strength and ductility. These improvements address key challenges that have hindered the widespread adoption of 3D-printed titanium in aerospace and medical device industries. The research introduces a novel framework for designing metallic alloys tailored specifically for additive manufacturing, moving beyond legacy alloys that limit the potential of 3D printing. The team has produced and tested samples at RMIT’s Advanced Manufacturing Precinct and is now seeking industry partners to help commercialize the alloy. A provisional patent has been filed for the
3D-printingtitanium-alloymaterials-scienceadditive-manufacturingaerospace-materialsmetal-alloyscost-effective-materialsUniversity of Waterloo researchers develop robots to directly treat kidney stones - The Robot Report
Researchers at the University of Waterloo, led by Dr. Veronika Magdanz, have developed a novel robotic technology aimed at directly treating kidney stones by dissolving them within the urinary tract. Kidney stones affect about 12% of people and often require prolonged drug treatments or surgeries, which can be painful and burdensome. The new minimally invasive approach uses thin, flexible, magnetically controlled strips about 1 cm long, embedded with the enzyme urease. These strips are maneuvered near uric acid kidney stones using a robotic arm guided by doctors, where the enzyme reduces urine acidity, accelerating stone dissolution so they can pass naturally within days. The technology was tested in life-size, 3D-printed urinary tract models and shows promise especially for patients who frequently develop stones or cannot tolerate oral medications or surgery due to risks like chronic infections. The system combines a motorized magnet on a robotic arm with real-time ultrasound imaging to precisely position the enzyme-loaded robots near the stones. Next steps for the
roboticsmedical-robotskidney-stone-treatmentrobotic-armminimally-invasive-surgerybiomedical-engineering3D-printingHeavy Metal Meets High Tides With 3D Printer - CleanTechnica
The article from CleanTechnica highlights a significant advancement in marine energy research enabled by a new laser-powered metal 3D printer at the National Renewable Energy Laboratory’s (NREL) Flatirons Campus. Marine energy devices, which harness power from ocean waves, currents, and tides, require metal components capable of withstanding extreme forces—up to five to ten times greater than plastics. However, the development of these devices has been hindered by the high costs and long timelines associated with designing, building, and testing full-scale metal prototypes. The new large-scale 3D metal printer addresses these challenges by rapidly producing a variety of metal components and near-full-scale structures (up to 1 meter long), allowing researchers to quickly iterate designs, reduce waste, and accelerate testing. This advanced 3D printer, customized by One-Off Robotics and funded by the U.S. Department of Energy, features eight axes—far surpassing the three-axis capability of conventional printers—enabling the creation of complex and
energymarine-energy3D-printingadditive-manufacturingprototypingmetal-componentsocean-energy-technologies$195,000 3D-Printed Housing Come To The US
The article discusses the emerging presence of affordable 3D-printed housing in the United States, focusing on a project in Austin, Texas. The company Icon, in collaboration with Michael Hsu Office of Architecture, is developing a community featuring homes constructed using 3D-printing technology. These homes are priced around $195,000, aiming to provide cost-effective housing solutions. This initiative highlights the potential for 3D printing to address housing affordability challenges by reducing construction time and costs. The Austin project serves as a test case for the viability and scalability of 3D-printed homes in the US market, signaling a possible shift in how residential buildings are designed and built in the future.
materials3D-printingconstruction-technologyaffordable-housingsustainable-materialsadditive-manufacturingWorld's first 3D-printed rocket part survives cryogenic pressure test
A team at the Korea Institute of Industrial Technology (KITECH) has successfully produced the world’s first large titanium rocket fuel tank using 3D printing, specifically the Directed Energy Deposition (DED) process. This 640mm diameter tank, made from Ti64 titanium alloy, was fabricated by melting titanium wire layer-by-layer with a laser, then assembling two hemispheres through machining and welding. The entire manufacturing cycle took only a few weeks, significantly faster than traditional forging methods, which rely on fixed molds and are less adaptable for custom, large-scale parts. The 3D-printed fuel tank passed a critical cryogenic pressure test conducted by the Korea Aerospace Research Institute (KARI), withstanding pressures of 330 bar at -196°C, conditions simulating spaceflight environments. This milestone demonstrates that large additively manufactured titanium structures can endure extreme temperatures and pressures required for space applications, potentially revolutionizing aerospace manufacturing by reducing costs, lead times, and design constraints. However, further cyclic
3D-printingtitanium-alloyaerospace-materialscryogenic-pressure-testadditive-manufacturingDirected-Energy-Depositionspace-fuel-tankIndian startup unveils world's largest single-piece 3D-printed rocket engine
Indian space-tech startup Agnikul Cosmos has developed the world’s largest single-piece 3D-printed rocket engine, measuring one meter in length and made entirely from Inconel, a high-performance nickel-chromium superalloy. This innovative engine is manufactured as a fully integrated, one-piece structure without welds, joints, or fasteners, which traditionally pose risks of failure in rocket engines. The 3D printing approach reduces manufacturing complexity and production time while enhancing structural integrity, marking a significant advancement in rocket engine design. Agnikul has also secured a US patent for this unique design and manufacturing method, underscoring India’s growing presence in the global aerospace sector. Founded in 2017 at the Indian Institute of Technology Madras, the company previously test-fired its first 3D-printed engine, Agnilet, in 2022. Agnikul’s latest development aims to offer more cost-effective, reliable, and rapidly produced rockets for on-demand space missions. The
3D-printingrocket-engineInconelsuperalloyaerospace-manufacturingadditive-manufacturingspace-technologyScottish brothers row 9,000 miles in F1-inspired boat across Pacific
Three Scottish brothers—Ewan, Jamie, and Lachlan Maclean—are undertaking a remarkable 9,000-mile unsupported row across the Pacific Ocean in a high-performance boat inspired by Formula One technology. Their vessel, named Emily-Rose, is a lightweight, carbon-fiber craft co-designed with the Ocean Rowing Company, weighing just 280 kilograms and constructed using F1-grade materials. The boat incorporates over 40 custom 3D-printed parts made with a Formlabs Form 4 printer and engineering resins, including ergonomic rowing seats, a removable bed, and mounts for satellite communication. This cutting-edge design allows the brothers to maximize efficiency, durability, and safety during their journey, which began in Lima, Peru, on April 13 and aims to reach Sydney, Australia, by early August. The Macleans trained for two years, preparing physically and mentally, and dehydrating over 1,000 meals to sustain their unsupported expedition. Their mission extends beyond breaking the world record for
materials3D-printingcarbon-fiberFormula-One-technologyocean-rowingengineering-resinscustom-partsRobot crab reveals how male crabs compete to attract female mates
A study conducted by researchers at the University of Exeter’s Centre for Research in Animal Behaviour (CRAB) used a robotic crab named Wavy Dave to investigate how male fiddler crabs compete for female mates. Male fiddler crabs attract females by waving their one oversized claw outside their burrows, a key sexual signal. The robotic crab, equipped with a 3D-printed body and waving claw, was placed near real male crabs in southern Portugal to observe their reactions to a mechanical rival. The study found that male crabs increased their claw-waving duration and were less likely to retreat when the robot waved, especially when it had a smaller claw, indicating that males adjust their signaling behavior dynamically in response to competition. The research also revealed that male crabs were less likely to challenge rivals with larger claws, likely due to fear of losing or injury. Some males even physically attacked the robotic crab, with one crab pulling off Wavy Dave’s claw and ending the trial. These behaviors suggest
robotroboticsanimal-behaviorrobotic-crab3D-printingbiomimicrycompetition-analysisNew study by US engineers improves strength prediction in 3D printing
A research team at the University of Maine, led by engineers Philip Bean, Senthil Vel, and Roberto Lopez-Anido, has developed a novel method to improve strength prediction in lightweight 3D-printed parts, focusing on the gyroid infill pattern. This pattern, commonly used in additive manufacturing to reduce weight while maintaining strength, was analyzed through a combination of advanced computer modeling and physical stress testing. The team validated their finite element analysis (FEA) simulations with real-world compression and shear experiments, resulting in semi-empirical equations that enable more convenient and accurate strength predictions for design and optimization purposes. This approach addresses limitations of traditional analytical methods that struggle with complex internal geometries, providing deeper insights into how gyroid infill distributes stress and contributes to overall structural performance. The improved predictive capability allows engineers to optimize designs by balancing material efficiency and structural integrity, reducing material usage without compromising strength. The breakthrough is expected to benefit industries requiring strong, lightweight components, such as aerospace, automotive, and
3D-printingadditive-manufacturingmaterials-sciencegyroid-infillstructural-strengthlightweight-materialsmechanical-engineeringLidris robot makes 3D floating illustrations inside drinks in real time
Suntory unveiled “Lidris,” an innovative robot that creates three-dimensional floating illustrations inside beverages in real time, at Expo 2025 in Osaka. The system injects food-safe, natural pigment-based inks—such as lycopene from tomatoes—into drinks like lemonade, forming suspended images that can remain visible for over an hour indoors. The technology integrates robotics, food science, and fluid mechanics to maintain the shape of the designs within the liquid, offering a novel and interactive drinking experience. Visitors at Suntory’s Park Café pavilion witnessed illustrations, including the fair’s mascot, appearing inside their drinks as they were served. Lidris is designed as a customizable beverage platform, allowing adjustments to flavors, colors, and alcohol content, making it suitable for a range of settings from private events to commercial venues. Its compact size (about 50 cm square) and simplified manual operation enable easy use by part-time staff, facilitating deployment in small cafés or event spaces. Beyond hospitality, the technology holds
robotroboticsbeverage-technologyfluid-mechanicsfood-scienceautomation3D-printingMIT vision system teaches robots to understand their bodies
MIT researchers at CSAIL have developed a novel robotic control system called Neural Jacobian Fields (NJF) that enables robots to learn how their bodies move in response to motor commands purely through visual observation, without relying on embedded sensors or hand-coded models. Using a single camera and random exploratory movements, NJF allows robots—ranging from soft robotic hands to rigid arms and rotating platforms—to autonomously build an internal model of their 3D geometry and control sensitivities. This approach mimics how humans learn to control their limbs by observing and adapting to their own movements, shifting robotics from traditional programming toward teaching robots through experience. NJF’s key innovation lies in decoupling robot control from hardware constraints, enabling designers to create soft, deformable, or irregularly shaped robots without embedding sensors or modifying structures for easier modeling. By leveraging a neural network inspired by neural radiance fields (NeRF), NJF reconstructs the robot’s shape and its response to control inputs solely from visual data. This
roboticsmachine-learningsoft-roboticsrobotic-control-systemsneural-networks3D-printingcomputer-visionMIT unveils 3D printer that turns food scraps into household items
Researchers at MIT have developed the FOODres.AI Printer, a novel 3D printer that transforms food waste—such as banana peels, eggshells, coffee grounds, and flower stems—into useful household items like coffee mugs, coasters, and small bowls. The process begins with users photographing their food scraps via a companion app that employs AI-powered image recognition to identify the waste type. The app then suggests printable object designs, and the printer converts the food waste into a bioplastic paste with natural additives. Using a heated extruder system, the printer shapes the paste into the selected item, making the technology accessible even to those without prior 3D printing experience. This innovation addresses the significant environmental issue of food waste, which in the U.S. amounted to 66 million tons in 2019, much of which contributes to greenhouse gas emissions when sent to landfills. By enabling households and communities to repurpose scraps into functional goods, the FOODres.AI Printer promotes a circular
3D-printingsustainable-materialsbioplasticsfood-waste-recyclingcircular-economyAI-in-manufacturingeco-friendly-technologyUK’s sixth-gen stealth fighter emerges as next-gen war machine
The UK’s Combat Air Flying Demonstrator marks the nation’s first piloted supersonic fighter aircraft developed in 40 years, spearheaded by the Ministry of Defence in partnership with BAE Systems, Rolls-Royce, and MBDA UK. Currently, two-thirds of the aircraft’s structural weight—including its main body, wings, and tail fins—is in production at BAE Systems’ Lancashire facilities, utilizing advanced manufacturing techniques such as robotic assembly, 3D printing, and digital twins. This demonstrator aims to test and mature technologies critical for a future sixth-generation stealth fighter jet under the Global Combat Air Programme, emphasizing stealth capabilities, advanced design approaches, and streamlined production processes. Extensive simulator flights totaling over 300 hours have allowed engineers and test pilots from BAE Systems, Rolls-Royce, and the RAF to evaluate flight control systems and gather performance data ahead of the aircraft’s maiden flight. Collaborative efforts have also included high-speed ejection seat trials with Martin Baker and aerodynamic engine testing
roboticsdigital-manufacturingadvanced-materialsaerospace-engineeringstealth-technology3D-printingdigital-twinsWatch: Student‑built 3D-printed drone flies, dives, and swims
A team of applied industrial electronics students at Aalborg University in Denmark has developed a 3D-printed hybrid drone capable of flying, diving underwater, maneuvering beneath the surface, and resurfacing rapidly in a seamless sequence. Central to this capability is a variable pitch propeller system that adjusts blade angles for optimal performance in air and water—higher pitch for flight to generate airflow, and lower pitch underwater to reduce drag and improve efficiency. These propellers also provide negative thrust for precise underwater control. The drone’s smooth transitions between air and water, captured in continuous video footage, highlight the effectiveness of this straightforward propeller-based approach. The prototype was designed, fabricated using 3D printing and CNC machining, and programmed by the students over two academic semesters under the guidance of associate professor Petar Durdevic. While hybrid drones are not entirely new, this project stands out for its polished demonstration of rapid, repeatable air-to-water transitions without complex mechanical reconfigurations. The students envision applications in military
robotdrone3D-printinghybrid-dronevariable-pitch-propellersunderwater-roboticsaerial-roboticsUS uses high-precision 3D printing for Gen IV nuclear reactor parts
The United States is pioneering the use of high-precision 3D printing to create polymer forms for concrete components in advanced nuclear reactors, marking a shift away from traditional steel or wood molds. At Kairos Power’s Oak Ridge campus in Tennessee, these 3D-printed molds are being employed for the Janus shielding demonstration, a test precursor to building parts of the Hermes Low-Power Demonstration Reactor. Hermes is notable as the first advanced reactor to receive a construction permit from the US Nuclear Regulatory Commission. The printed forms, each about 10 feet square and stacked three high, are used to cast the reactor’s bioshield—a thick concrete structure designed to absorb radiation and protect workers during operation. This additive manufacturing approach offers a cost-effective and time-efficient alternative to conventional methods, enabling the construction of complex geometries with high structural integrity under the pressure of wet concrete. The project, a collaboration involving Oak Ridge National Laboratory (ORNL), Kairos Power, and the Manufacturing Demonstration Facility (
energynuclear-energy3D-printingadditive-manufacturingadvanced-reactorsconstruction-technologymaterials-engineeringCold War bunker in UK reborn as advanced rocket test facility
A former Cold War-era armored building near the Mull of Kintyre in the UK has been transformed into MachLab, an advanced rocket test and teaching facility. Originally part of a US Air Force refueling complex in the late 1980s, the structure’s robust design now provides a secure environment for experimental rocket engine firings. Located on the former RAF Machrihanish airbase, MachLab was developed through a collaboration between the University of Glasgow and industry partners, securing around £500,000 in funding, including support from the UK Space Agency. The facility is equipped to test rocket engines producing up to one tonne of thrust and aims to advance rocket propulsion research. MachLab also focuses on training the next generation of UK rocket engineers through programs like the Rocketry Research Teaching Training (R2T2) initiative led by the University of Glasgow. The facility supports the development of engines using various propellants—solid, liquid, and cryogenic—and provides detailed data collection on parameters such as
energyrocket-propulsionaerospace-materials3D-printingrocket-enginesspace-technologyadvanced-cooling-systemsUK nuclear fusion labs to get 3D boost to build tougher reactor parts
The United Kingdom Atomic Energy Authority (UKAEA) has commissioned two advanced 3D printing machines to produce components for future nuclear fusion reactors capable of withstanding extreme conditions such as high heat, intense neutron radiation, and strong magnetic fields. These machines, housed at the new Central Support Facility, include an electron beam powder bed fusion (E-PBF) system from Freemelt designed to fuse tungsten powder into dense, ultra-tough plasma-facing parts, and a selective laser melting (SLM) machine from Nikon SLM Solutions for fabricating complex geometries and material combinations. Both additive manufacturing methods aim to reduce reliance on traditional fabrication techniques like welding, streamlining production and enhancing precision. UKAEA emphasizes that additive manufacturing is critical for producing the thousands or millions of specialized components required for commercial fusion power plants, as it allows for intricate designs in small volumes with improved efficiency and potentially lower costs. The dual capability of electron beam and laser-based 3D printing under one roof is a pioneering step for the
energynuclear-fusion3D-printingadditive-manufacturingtungstenreactor-componentsmaterials-engineering3D-printed steel endures month-long trial in extreme nuclear reactor
Researchers at Oak Ridge National Laboratory (ORNL) have successfully tested 3D-printed capsules made from 316H stainless steel in the High Flux Isotope Reactor (HFIR), one of the world’s most intense neutron flux environments. These capsules, produced using a laser powder-bed fusion additive manufacturing process, were designed to hold sample materials during irradiation experiments that simulate extreme nuclear reactor conditions. After a month-long irradiation period, the capsules remained fully intact, demonstrating that additively manufactured components can meet the stringent safety and performance standards required in nuclear environments. This milestone highlights the potential for additive manufacturing to revolutionize the production of critical nuclear reactor components by significantly reducing fabrication time and costs compared to traditional methods. The 316H stainless steel used offers high-temperature strength, corrosion and radiation resistance, and proven nuclear-grade weldability. The success of this test paves the way for broader adoption of 3D printing in nuclear materials and fuels research, enabling faster innovation and qualification of advanced reactor technologies. The
3D-printingstainless-steelnuclear-reactoradditive-manufacturingmaterials-testingirradiation-experimentsenergy-materialsElephant robot mimics muscle and bone with foam lattice design
Engineers at EPFL have developed a groundbreaking programmable foam lattice that combines softness and rigidity to mimic the musculoskeletal system of animals, enabling robots to bend, twist, and bear weight with unprecedented precision. This innovation was demonstrated through an elephant-inspired robot featuring a soft, twisting trunk and jointed limbs with varying stiffness, achieved by using two main types of foam cells—body-centered cubic (BCC) and X-cube—that can be blended continuously across the robot’s structure. This design allows smooth transitions between flexible and rigid areas, similar to how muscles transition into tendons and bones in animals. The programmable foam lattice offers immense configurational flexibility, with millions of possible geometric combinations by rotating, shifting, or superimposing individual foam cells. This capability enabled the creation of diverse joint types in the elephant robot, such as sliding, bending, and biaxial joints, facilitating lifelike movements like trunk twisting and leg articulation. Beyond locomotion, the lattice’s high strength-to-weight ratio and open foam structure
roboticssoft-roboticsprogrammable-foam3D-printingbiomimicrylattice-structuresmusculoskeletal-systemUS student's rope-driven robot dog walks naturally with clever math
A mechanical engineering student from Purdue University, Aaed Musa, has developed an innovative quadrupedal robot dog named CARA, distinguished by its rope-driven capstan drive system rather than traditional gears or pulleys. CARA, which stands for "Capstans Are Really Awesome," uses tensioned high-strength Dyneema DM20 ropes wrapped around smooth drums to transfer motion and torque, offering benefits such as zero backlash, high torque transparency, low inertia, low cost, and quiet operation. The robot incorporates 12 brushless pancake motors (three per leg), custom 3D-printed parts made from durable materials like PET and carbon fiber, carbon fiber tubes for lightweight strength, and ODrive S1 motor controllers for precise control. Its brain is a Teensy 4.1 microcontroller, supported by sensors including a BNO086 IMU for 3D orientation, all powered by a portable 24-volt battery. CARA’s movement is governed by inverse kinematics (IK)
robotroboticsrope-driven-robotquadrupedal-robotcapstan-drive3D-printingbrushless-motorsUS lab plans dual-material 3D printing to boost aircraft, energy tech
Oak Ridge National Laboratory (ORNL), in partnership with JuggerBot 3D, is developing a novel dual-material 3D printing system capable of processing both thermoplastic and thermoset polymers in a single manufacturing process. This hybrid approach aims to combine the flexibility and ease of thermoplastics with the superior thermal and chemical resistance of thermosets, enabling the production of complex parts with varied material properties. The project builds on prior work that improved large-format thermoplastic printing by refining ORNL’s open-source slicing software and integrating a laser-based real-time calibration system, which enhanced print consistency and reduced the need for post-processing. A significant advancement from the initial collaboration was the automation of material setup through a “Material Card” database, which stores process parameters for different materials. This innovation, paired with ORNL’s Slicer 2 software and calibration technology, streamlines operations by eliminating the need for repeated calibration when switching materials, saving considerable time. The current focus is on adapting this framework to
3D-printingadditive-manufacturingdual-material-printingthermoplasticsthermosetsenergy-technologyOak-Ridge-National-LaboratoryScientists develop algae-based concrete that captures 142% more carbon
Researchers at the University of Pennsylvania have developed an innovative algae-based concrete that significantly reduces environmental impact while maintaining structural integrity. By incorporating diatomaceous earth—powder made from fossilized silica shells of microscopic algae—into a 3D-printed concrete mix, the team created a lightweight material that uses 68% less cement and absorbs 142% more CO₂ compared to traditional concrete. This breakthrough leverages the natural carbon-trapping abilities of diatoms and a mathematically optimized internal geometry inspired by coral reefs and sea stars, known as triply periodic minimal surfaces (TPMS), which maximize surface area and stiffness with minimal material. The new concrete not only captures more carbon dioxide but also grows stronger over time during curing, retaining 90% of the strength of conventional solid concrete blocks despite its high porosity. The design incorporates post-tensioning cables and advanced force-balancing geometries to ensure durability and buildability at architectural scales. The researchers are currently scaling up the technology for larger applications such
materialsconcretecarbon-capturesustainable-construction3D-printingdiatomaceous-earthcarbon-dioxide-absorptionQatar turns desert sand into the world’s largest 3D printed structure
Qatar has embarked on constructing the world’s largest 3D-printed buildings—two public schools each covering 20,000 square meters—using massive custom-built printers from Denmark’s COBOD. This project, part of a larger plan to build 14 schools totaling 40,000 square meters, represents a 40-fold increase in scale compared to the previous largest 3D-printed structure, a 10,000-square-foot equestrian facility in Florida. The printers, each the size of a Boeing 737 hangar, extrude specialized concrete layer by layer to create walls with flowing, dune-like curves inspired by Qatar’s desert landscape. Over the past eight months, a multidisciplinary team in Doha has conducted more than 100 full-scale test prints, optimizing concrete mixes and printer technology to withstand Qatar’s harsh climate. Printing primarily occurs at night to enhance material performance and reduce environmental impacts such as dust, noise, and energy use. The project not only pushes the boundaries of large-scale additive
3D-printingconstruction-technologymaterials-scienceadditive-manufacturingconcrete-innovationdigital-constructioninfrastructure-developmentMan’s deadly chest ‘time bomb’ removed using 3D-printed aorta model
Surgeons at Brisbane’s Prince Charles Hospital successfully performed a rare and complex operation to replace nearly the entire aorta of a man in his late 50s, whose vessel had ballooned to about four times its normal size, posing an imminent risk of fatal rupture. The life-threatening condition, described as a “ticking time bomb,” was discovered during routine monitoring. To prepare for the intricate nine-hour surgery, the team collaborated with the Herston Biofabrication Institute to create a life-sized, multi-material 3D-printed model of the patient’s distorted aorta. This tactile model, produced from detailed CT scans, allowed surgeons to rehearse the procedure more effectively than traditional two-dimensional imaging. During surgery, the patient’s body was cooled and circulation temporarily stopped to enable safe removal of the diseased aortic arch, which had expanded to about eight centimeters—far beyond the normal two to three centimeters. The damaged section was replaced with a synthetic graft resembling “flexible, waterproof jackets.”
3D-printingsynthetic-graftmedical-materialsbiofabricationvascular-surgerymulti-material-printingmedical-technology3D-printed jet engine hits 13,000 feet in China’s maiden flight test
China has successfully conducted the maiden flight test of its first fully 3D-printed mini turbojet engine, which reached an altitude of 13,000 feet (4,000 meters) in the Inner Mongolia Autonomous Region. This 160-kilogram thrust-class engine was produced using a combination of additive manufacturing and multi-disciplinary topology optimization, allowing for complex, lightweight, and integrated components that traditional casting and forging methods cannot easily achieve. The development represents a significant technical milestone for China’s aerospace sector, potentially reducing its reliance on foreign-sourced engines and addressing longstanding challenges in metallurgy and precision engineering. While additive manufacturing is already established in the aerospace industry globally—with companies like GE Aviation and Pratt & Whitney using 3D-printed parts—China’s achievement lies in producing an entire flight-validated engine through these methods. The lightweight engine is expected to be particularly useful for unmanned aerial vehicles (UAVs). However, transitioning from a prototype to industrial-scale production poses challenges, including advancements in high-temperature
3D-printingadditive-manufacturingaerospace-materialsjet-engine-technologyadvanced-manufacturingmaterials-engineeringaerospace-innovationMIT student’s pocket-sized 3D printer can craft objects in seconds
Researchers at MIT, led by PhD candidate Sabrina Corsetti and Professor Jelena Notaros, have developed a groundbreaking pocket-sized 3D printer based on a single millimeter-scale photonic chip. This chip uses light to create solid objects within seconds by emitting reconfigurable visible-light holograms into a stationary resin well, enabling non-mechanical 3D printing without any moving parts. The innovation combines silicon photonics and photochemistry to achieve rapid fabrication of customized, low-cost objects, marking the first demonstration of chip-based 3D printing. This compact and portable system addresses many limitations of traditional 3D printers, which rely on large mechanical setups that restrict speed, resolution, and form factor. Beyond 3D printing, the team also created a miniature “tractor beam” using light to manipulate biological particles, offering new possibilities for contamination-free biological research. The researchers anticipate that their chip-based technology could revolutionize manufacturing across diverse fields such as military, medical, engineering, and consumer applications
materials3D-printingphotonicssilicon-photonicsphotochemistryoptical-tweezersmanufacturing-technology‘Shocking’ 3D resin may build soft robots with plastic-like strength
Researchers at the University of Texas at Austin have developed an innovative 3D printing technique that uses a custom liquid resin and a dual-light system to create objects combining both soft, rubber-like flexibility and hard, plastic-like strength within a single print. Inspired by natural structures such as human bones and cartilage, this method employs violet light to produce flexible material and ultraviolet light to harden the resin, enabling seamless transitions between soft and rigid zones without weak interfaces. This breakthrough addresses common issues in multi-material printing where different materials often fail at their boundaries. Demonstrations of the technology included printing a functional knee joint with soft ligaments and hard bones that moved smoothly together, as well as a stretchable electronic device with flexible and stiff areas to protect circuitry. The researchers were surprised by the immediate success and the stark contrast in mechanical properties achieved. An adjacent study published in ACS Central Science further highlights the potential of light-driven resin chemistry to advance additive manufacturing, offering faster production, higher resolution, and new design freedoms.
3D-printingsoft-roboticsadvanced-materialsresin-technologyflexible-electronicsdual-light-curingmaterial-scienceMIT's new AI outsmarts human design to help robots jump 41% higher
MIT’s Computer Science and Artificial Intelligence Laboratory (CSAIL) has developed a new generative AI approach that designs robots capable of jumping 41% higher than those created by human engineers. Using diffusion-based generative models, researchers allowed the AI to modify specific parts of a 3D robot model, resulting in curved linkages resembling thick drumsticks rather than the straight, rectangular parts of traditional designs. This unique shape enabled the robot to store more energy before jumping, improving performance without compromising structural integrity. The AI-assisted robot also demonstrated an 84% reduction in falls compared to the baseline model, highlighting enhanced stability and landing safety. The process involved iterative refinement, with the AI generating multiple design drafts that were scaled and fabricated using 3D-printable polylactic acid material. Researchers believe that future iterations using lighter materials could achieve even higher jumps. Beyond jumping robots, the team envisions applying diffusion models to optimize how parts connect and to design robots with more complex capabilities, such as directional control and
roboticsartificial-intelligencegenerative-AIrobot-design3D-printingmaterials-sciencerobotics-innovationUS: World’s most advanced rocket engine tested for hypersonic drones
The US startup New Frontier Aerospace (NFA) has successfully completed critical fire tests of its Mjölnir rocket engine, a cutting-edge propulsion system designed for next-generation hypersonic drones and space vehicles. Unlike most aerospace engines that use RP-1 or liquid hydrogen, Mjölnir runs on liquid natural gas (LNG), which is a cleaner-burning fuel and can become net carbon-negative when sourced from bio-waste. The engine features a full-flow staged combustion cycle—an advanced architecture that improves efficiency, thrust-to-weight ratio, and engine longevity—and is 3D-printed to reduce manufacturing costs and enable rapid development. Supported by NASA and the Defense Innovation Unit, Mjölnir demonstrated stable ignition, precise throttle control, and consistent thermal performance, confirming its reliability as a main propulsion system. Mjölnir is set to power two key NFA platforms: Pathfinder, a hypersonic vertical takeoff and landing (VTOL) unmanned aerial system aimed at rapid military
energyrocket-enginehypersonic-dronesliquid-natural-gasaerospace-propulsion3D-printingsustainable-fuelSynthetic lichen could 3D print homes on Mars using Martian soil
Researchers led by Dr. Congrui Grace Jin at Texas A&M University have developed a synthetic lichen system that could autonomously create building materials on Mars using only Martian soil simulant, air, light, and an inorganic liquid medium. This bio-manufacturing approach mimics natural lichens, which are symbiotic communities of fungi and cyanobacteria. The cyanobacteria fix carbon dioxide and nitrogen from the Martian atmosphere, producing oxygen and nutrients, while the fungi bind metal ions and help form biominerals. Together, they secrete biopolymers that glue Martian regolith particles into solid structures, enabling the creation of building materials without human intervention or external nutrient supplies. This innovation addresses major challenges in extraterrestrial construction by eliminating the need to transport heavy materials from Earth or rely on continuous human assistance. Funded by NASA’s Innovative Advanced Concepts program, the technology promises to facilitate autonomous 3D printing of habitats, furniture, and other structures on Mars. The team is currently
materials3D-printingsynthetic-lichenMartian-soilbio-manufacturingspace-constructionbiomaterialsRevolutionary 3D magnet setup could slash MRI costs and boost access
German physicists from the University of Bayreuth and Johannes Gutenberg University Mainz have developed a novel magnetic field design that surpasses the traditional Halbach array by delivering stronger, cheaper, and more uniform magnetic fields in a compact setup. Their innovation involves arranging 16 tiny neodymium (FeNdB) magnet cuboids in optimized three-dimensional orientations on 3D-printed supports, forming single or stacked double rings. This focused design maintains magnetic field strength and uniformity not only within the magnet plane but also above it, addressing a key limitation of the Halbach array, which struggles to produce uniform fields in finite-sized, practical applications. This breakthrough holds significant promise for technologies requiring stable, homogeneous magnetic fields, particularly medical imaging. Conventional MRI machines rely on costly, complex superconducting magnets that require cryogenic cooling, limiting access in rural and underserved regions. The new permanent magnet configuration offers a low-cost, energy-efficient alternative that could make MRI technology more accessible in remote clinics, mobile health units, and
materialsmagnet-design3D-printingneodymium-magnetsMRI-technologymagnetic-fieldsmedical-imagingScientists 3D-print thermal insulation fibres from wheat straw
Researchers led by Dr. Chi Zhou at the University at Buffalo have developed a sustainable thermal insulation material by 3D-printing fibers derived from wheat straw, an agricultural byproduct typically burned after harvest. Wheat straw’s natural fibrous and porous structure provides effective thermal insulation, high mechanical strength, and enhanced flame retardancy compared to other organic materials. The process involves pulping wheat straw into a slurry, drying it into a thick ink, and cross-linking the fibers with an organic binder to ensure material integrity before 3D printing. This innovation offers a renewable, biodegradable alternative to conventional insulation materials like glass and rock wool, which rely heavily on fossil fuels and contribute to greenhouse gas emissions. To address the slow printing speed of early methods, Zhou’s team redesigned the 3D printer with a slot-die nozzle and multiple nozzles for faster, more uniform material deposition, making the process scalable for industrial production. Using wheat straw not only reduces environmental impact by lowering emissions and decreasing agricultural waste but
materials3D-printingthermal-insulationsustainable-materialswheat-strawbiomasseco-friendly-materialsLive bacteria-infused sustainable building material traps CO2 from air
Researchers at ETH Zurich have developed an innovative, sustainable building material infused with live cyanobacteria that actively captures atmospheric carbon dioxide through photosynthesis and biocementation. This 3D-printed hydrogel-based material houses photosynthetic bacteria within a polymer network designed to optimize light, CO2, water, and nutrient flow, enabling the bacteria to remain productive for over a year. The material sequesters CO2 both biologically and by forming stable mineral carbonates, which strengthen the initially soft gel into a robust, hardened structure over time. Laboratory tests demonstrated that the material can bind approximately 26 milligrams of CO2 per gram, outperforming typical biological methods and rivaling chemical mineralization in recycled concrete. The technology has moved beyond the lab, with large-scale installations such as the "Picoplanktonics" exhibit at the Architecture Biennale in Venice, featuring three-meter-high structures capable of capturing up to 18 kilograms of CO2 annually—comparable to a mature pine tree.
materialssustainable-buildingcarbon-captureliving-materialscyanobacteria3D-printingbiocementationNew 3D-printed off-roading robot made from recycled materials
A European collaboration between Lemki Robotix (Ukraine), iSCALE 3D (Germany), and Zeykan Robotics (Czech Republic) has unveiled the world’s first fully 3D-printed autonomous off-road robot made entirely from recycled materials. The robot’s body, wheels, and rims are fabricated using reinforced recycled polymers—glass fiber-reinforced recycled polypropylene for the sealed body, puncture-proof recycled polyurethane for airless wheels, and carbon fiber-reinforced nylon for rims—ensuring durability in harsh outdoor environments. Equipped with 360° cameras, LiDAR, and Starlink satellite connectivity, it supports real-time remote operation and autonomous navigation via an onboard neural network, capable of functioning even in GPS-denied areas. Designed for challenging applications such as military logistics, search and rescue, precision agriculture, and infrastructure inspection, the hermetically sealed robot can cross shallow water and operate reliably in demanding conditions. This project exemplifies the potential of large-format 3D printing to
robot3D-printingrecycled-materialsautonomous-robotoff-road-robotsustainable-roboticsneural-networksAI co-designs a jumping robot that outperforms its human-made twin
Researchers at MIT’s Computer Science & Artificial Intelligence Laboratory (CSAIL) have developed a novel system leveraging generative AI, specifically diffusion models, to co-design robots by optimizing their mechanical structures through iterative simulation and fabrication. This approach allows users to input a 3D model and specify modifiable components, enabling the AI to generate and test numerous design variants before physical production. In a key demonstration, the AI-designed jumping robot outperformed a human-designed counterpart by jumping 41% higher, achieved through innovative curved, drumstick-like linkages that were lighter yet stronger and had greater energy capacity. Additionally, the AI improved the robot’s foot design, enhancing landing stability by 84%, significantly reducing falls. This breakthrough highlights the potential of diffusion models to reveal new insights into structural physics and accelerate hardware design processes, which traditionally lag behind software development due to complexity and manufacturing constraints. By balancing competing objectives such as jump height and landing success, the AI system produced optimized designs that blend human intuition with machine precision.
roboticsAI-designgenerative-AI3D-printingrobot-optimizationdiffusion-modelsrobotic-hardwareFirst-time maker’s 3D-printed drone could fly 130 miles in 3 hours
Engineer Tsung Xu, a first-time maker with no formal background in aerodynamics or 3D printing, successfully designed and built a fully functional vertical takeoff and landing (VTOL) fixed-wing drone capable of flying 130 miles (209.2 km) in about 3 hours. Completed in just 90 days, Xu’s project involved designing, modeling, and 3D printing every aerodynamic surface and structural component from scratch using a consumer-grade Bambu Lab A1 desktop 3D printer. Non-printable elements such as motors, radio equipment, and electronic speed controllers were sourced separately and integrated into the system, which is powered by a high-energy-density lithium battery to maximize endurance. The drone’s VTOL capability allows it to take off and land vertically without a runway, then transition to efficient forward flight, a feature typically found in advanced military or commercial unmanned aerial systems. Xu’s achievement demonstrates how accessible technologies like desktop 3D printing and off-the-shelf components can enable
robotdrone3D-printinglithium-batteryVTOLaerospace-engineeringunmanned-aerial-systemsWorld's first test shakes 3D-printed homes to check earthquake safety
The University of Bristol has conducted the world’s first large-scale earthquake safety test on a 3D-printed concrete home using the UK’s largest shaking table. This experiment aimed to evaluate whether 3D-printed homes can withstand seismic forces, addressing concerns about the structural integrity of this emerging construction method. By subjecting a quasi-real-scale 3D-printed concrete unit to progressively intense shaking, researchers closely monitored its response to identify potential weaknesses such as cracking or displacement. The goal is to compare 3D-printed structures with traditional buildings, validate computational seismic models, and ultimately determine if 3D-printed concrete can meet current earthquake safety standards. The project, led by Dr. De Risi, seeks to optimize design parameters like layer bonding and reinforcement integration to improve seismic performance. These findings are intended to inform engineers, architects, and policymakers, potentially leading to new building codes that incorporate additive manufacturing technologies. As 3D printing gains popularity for its affordability and sustainability, this research addresses
3D-printingearthquake-safetyconstruction-technologymaterials-scienceconcrete-innovationseismic-testingadditive-manufacturingUK inventor's Transformers-styled robot becomes shape-shifting vehicle
British inventor James Bruton has created a functional, rideable Transformer-style robot that can smoothly shift between humanoid and vehicle forms. Unlike many previous Transformer replicas that lack passenger space, Bruton's design allows him to ride the robot like a kid’s Power Wheels car. The robot incorporates 16 motors—including RC servos, Dynamixel servos, and DC brushed motors—and uses a Teensy microcontroller to control folding body panels, wheel movement, and LED lighting. Its legs are primarily decorative, and the robot folds into a fully operational electric vehicle capable of carrying Bruton at modest speeds. Bruton’s invention showcases practical engineering with a focus on stability, reliability, and refined aesthetics. The robot’s lightweight aluminum extrusion frame supports significant weight while maintaining nimbleness, and 3D printing has enabled rapid design iteration. To address challenges like shifting center of gravity during transformation, Bruton implemented a robust suspension system and balanced weight distribution. While the robot cannot yet walk in humanoid form, it represents
robotroboticselectric-motors3D-printingmicrocontrollershape-shifting-vehicleengineering-innovationUS scientists develop real-time defect detection for 3D metal printing
Scientists from Argonne National Laboratory and the University of Virginia have developed a novel method to detect defects, specifically keyhole pores, in metal parts produced by 3D printing using laser powder bed fusion. Keyhole pores are tiny internal cavities formed when excessive laser energy creates deep, narrow holes that trap gas, compromising the structural integrity and performance of critical components such as aerospace parts and medical implants. The new approach combines thermal imaging, X-ray imaging, and machine learning to predict pore formation in real-time by correlating surface heat patterns with internal defects captured via powerful X-rays. This method leverages existing thermal cameras already installed on many 3D printers, enabling instant detection of internal flaws without the need for continuous expensive X-ray imaging. The AI model, trained on synchronized thermal and X-ray data, can identify pore formation within milliseconds, allowing for immediate intervention. Researchers envision integrating this technology with automatic correction systems that adjust printing parameters or reprint layers on the fly, thereby improving reliability, reducing waste, and enhancing safety in manufacturing mission-critical metal parts. Future work aims to expand defect detection capabilities and develop repair mechanisms during the additive manufacturing process.
3D-printingmetal-additive-manufacturingdefect-detectionmachine-learningthermal-imagingX-ray-imagingmaterials-scienceUS turns recycled scrap into 3D-printed rocket parts with AI boost
robotmaterials3D-printingAIadditive-manufacturingrecycled-materialssustainable-manufacturingUS Army creates 3D-printed skin to heal combat wounds, fight bugs
materialsbioprintingbiomaterialsbiomedical-technologies3D-printingmilitary-technologytissue-engineeringUS nuclear fusion gets a 3D printing boost to fast-track construction
energynuclear-fusion3D-printingconstructionplasma-physicsmagnet-systemsNSTX-UNew human spine-inspired neck could revolutionize humanoid robots
robothumanoid-robotsanimatronicsengineering3D-printinglinear-actuatorsartificial-spinePhotos: World's tallest 3D-printed tower blends tech, art, and climate
robotics3D-printingdigital-designarchitectureconstruction-technologyCO₂-capturematerials-scienceCan the Cadillac Celestiq EV make GM’s luxury brand great again? Don’t rule it out
energyelectric-vehicleCadillacluxury-carbattery-technologyautomotive-design3D-printingCan the Celestiq EV make Cadillac great again? Don’t rule it out
electric-vehicleEVbattery-technologyluxury-carsautomotive-design3D-printingCadillacHugging Face releases a 3D-printed robotic arm starting at $100
Hugging-Facerobotic-arm3D-printingprogrammable-roboticsAI-technologyLeRobotSO-101