Articles tagged with "additive-manufacturing"
BASF starts world’s first plant to mass-produce 3D-printed catalysts
BASF has launched the world’s first industrial-scale plant dedicated to mass-producing 3D-printed catalysts, located in Ludwigshafen. This facility utilizes additive manufacturing, specifically BASF’s X3D technology, to create catalysts with complex internal geometries that were previously unattainable through conventional methods. These advanced designs improve gas and liquid flow within reactors by reducing resistance and increasing the active surface area where chemical reactions occur. As catalysts are crucial for accelerating reactions in producing fuels, fertilizers, and industrial chemicals, these enhancements are expected to significantly boost throughput and reduce energy consumption in large-scale chemical manufacturing. The new plant aims to scale up production capacity and accelerate the deployment of these innovative catalysts to a broader customer base. BASF highlights that the technology is versatile, applicable to catalysts made from both precious and base metals, and has already demonstrated success in real-world applications, such as the sulfuric acid catalyst plant operated by An Hui Jintung in China. By tailoring catalyst designs to specific chemical processes,
materials3D-printingcatalystschemical-manufacturingenergy-efficiencyadditive-manufacturingindustrial-productionNew 3D printing technology uses light to fine-tune material properties
Researchers at Savannah River National Laboratory, in collaboration with university and national lab partners, have developed a novel 3D printing technology called CRAFT (Lithographic Crystallinity Regulation in Additive Fabrication of Thermoplastics). This method uses a single light source to precisely control the molecular structure of polymers during printing by adjusting light intensity in real time. Unlike traditional 3D-printed parts that have uniform material properties, CRAFT enables the creation of objects with spatially varying characteristics such as strength, flexibility, and durability within a single print. For example, a single printed object can have sections as hard as bone and others as soft as skin, all achieved without harsh chemicals or extreme heat. The technology was demonstrated by printing a soft-bodied turtle with varying flexibility and a detailed human hand model featuring rigid bones, resilient ligaments, and pliable skin—all in one continuous print using a single material. This breakthrough has significant implications for multiple industries, including aerospace, energy, and biomedicine, by
3D-printingmaterials-sciencepolymer-engineeringadditive-manufacturinglight-based-fabricationmaterial-propertiesthermoplasticsUS lab drives nuclear innovation with 3D-printed reactor components
The US Argonne National Laboratory (ANL) has made a significant breakthrough in nuclear energy innovation by advancing the use of Laser Powder Bed Fusion (LPBF), a high-precision 3D printing method, for manufacturing high-temperature reactor components. This development, supported by a draft Code Case submitted to the American Society of Mechanical Engineers, aims to accelerate the approval and adoption of next-generation nuclear reactor parts. LPBF enables the production of complex, high-performance metal parts with precise control over material properties and geometry, overcoming limitations of traditional fabrication methods like forging and casting. This technology promises to enhance component performance, improve resistance to heat and radiation, reduce material waste, shorten production timelines, and strengthen the nuclear supply chain through localized, on-demand manufacturing. The project is a collaborative effort among several national laboratories under the US Department of Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program, which focuses on modern manufacturing techniques such as LPBF, Directed Energy Deposition, and Powder Metallurgy Hot Isost
nuclear-energy3D-printingadditive-manufacturingLaser-Powder-Bed-Fusionadvanced-materialsreactor-componentssupply-chain-innovationMetallic glass materials could help drones fly longer on less power
Researchers at Saarland University in Germany, led by Professor Ralf Busch, are developing metallic glass materials to improve the efficiency of electric motors used in drones, e-bikes, and household electronics. Conventional motors suffer from energy losses known as "iron loss," caused by internal friction when magnetic fields repeatedly reverse direction in crystalline iron alloys. Metallic glasses, which have a disordered atomic structure rather than an ordered crystal lattice, reduce these losses significantly because their magnetic regions can reorient more easily during magnetization cycles. The team focuses on soft magnetic alloys containing 70 to 80 percent iron, designed to remain amorphous and avoid crystallization during manufacturing. They employ metal 3D printing to produce motor parts layer by layer from powdered metallic glass, carefully controlling cooling to maintain the amorphous structure. Unlike typical glass, metallic glass is strong and not brittle. After testing hundreds of alloys, the researchers identified three suitable candidates compatible with 3D printing and possessing the desired magnetic properties. This work is
metallic-glassamorphous-metalselectric-motorsenergy-efficiencydrone-technologysoft-magnetic-materialsadditive-manufacturingNew 'super foam' absorbs 10× more energy using 3D-printed skeleton
Researchers at Texas A&M University and the DEVCOM Army Research Laboratory have created a hybrid "super foam" that absorbs up to 10 times more energy than conventional foam padding. This innovative material integrates ordinary open-cell foam with a 3D-printed internal skeleton of flexible plastic struts, produced via a process called In-Foam Additive Manufacturing (IFAM). The embedded lattice structure reinforces the foam, allowing it to better distribute and absorb impact forces while remaining lightweight. By tuning the diameter, spacing, and angles of the struts, the mechanical properties of the composite can be customized for different applications. The development aims to enhance protective gear, particularly military helmets, by providing superior impact absorption without adding significant weight, thereby improving soldier comfort and mobility. Beyond defense, the hybrid foam has potential uses in commercial helmets, vehicle interiors, bumpers, and consumer products like mattresses and cushions, where zones of firmness and comfort can be tailored. Researchers are also investigating its ability to absorb sound and vibrations,
materialsenergy-absorption3D-printingcomposite-materialsprotective-gearadditive-manufacturingimpact-resistanceUS firm tests upgraded Hadley H13 rocket engine for hypersonic flight
Ursa Major, a US aerospace and defense company, has successfully conducted the first hot-fire tests of its upgraded Hadley H13 liquid rocket engine, designed for hypersonic flight and small launch vehicles. The H13 is an enhanced version of the flight-proven Hadley H11 engine, delivering approximately 5,000 lbs of thrust at sea level and about 6,500 lbs in vacuum. Running on liquid oxygen and kerosene with an oxygen-rich staged combustion cycle, the engine features significant design improvements, updated materials, and advanced manufacturing processes—including 80% additive manufacturing—that increase performance, reusability, and reduce production lead times and costs. The H13 can be reused more than twice as many times as previous variants, making it Ursa Major’s highest performing and lowest cost-per-flight engine to date. The Hadley H13 is designed as an off-the-shelf propulsion solution, enabling integration into multiple platforms without custom development, thus supporting diverse mission profiles with greater reliability and
energyrocket-enginehypersonic-flightadditive-manufacturingreusable-propulsionliquid-oxygenaerospace-materialsPentagon tests 3D-printed scramjet, demonstrating Mach 5+ cruise
The Pentagon's Defense Innovation Unit (DIU) advanced hypersonic testing by launching a 3D-printed scramjet testbed, the DART AE, developed by Australian firm Hypersonix, as part of its HyCAT program. The Cassowary Vex mission used Rocket Lab’s HASTE vehicle to conduct a suborbital flight, gathering critical propulsion, trajectory, and vehicle data under real hypersonic conditions exceeding Mach 5. This marked the first deployment of a commercially developed testbed under DIU’s Hypersonic High-Cadence Advanced Testing initiative, aiming to accelerate hypersonic system validation while reducing costs and increasing flight frequency. The DART AE demonstrator features a gaseous hydrogen-fueled scramjet engine and an airframe entirely produced through additive manufacturing with high-temperature alloys, potentially broadening the hypersonic test supply chain. The HyCAT program, launched in 2022, addresses testing bottlenecks caused by limited U.S. facilities
3D-printingscramjethypersonic-testingadditive-manufacturinghigh-temperature-alloysaerospace-materialsdefense-technologyHow AI inverse design and 4D printing are shaping mechanical metamaterials
The article discusses the transformative impact of combining AI-driven inverse design with 4D printing technology in the development of mechanical metamaterials—materials whose mechanical properties are governed by their geometry rather than their chemical composition. Researchers, notably Dr. Xiaoyu “Rayne” Zheng’s team at UC Berkeley, have developed machine-learning algorithms that allow designers to specify desired mechanical responses, such as stress–strain curves, stiffness profiles, or energy absorption characteristics. The AI then generates a microarchitecture that can be fabricated via advanced additive manufacturing, achieving performance accuracies close to 90%. This approach enables the creation of novel material behaviors unattainable with natural materials, representing a paradigm shift in materials design. 4D printing complements this AI-driven design by using smart materials—such as shape-memory polymers, stimuli-responsive hydrogels, and liquid crystal elastomers—that respond dynamically to external stimuli like heat, moisture, or light. This allows printed metamaterials to self-assemble, shape-shift, and adapt over time,
materials4D-printingmechanical-metamaterialsAI-designadditive-manufacturingsmart-materialsshape-memory-polymersPhotos: Japan debuts first approved 3D-printed house with earthquake-ready frame
Japan has unveiled its first government-approved two-story 3D-printed reinforced concrete house, the O House, developed by Kizuki Co. Ltd. and architectural studio Onocom. This 50-square-meter residence combines robotic 3D printing with a conventional reinforced concrete frame to meet Japan’s stringent seismic building standards. The hybrid construction approach features a reinforced strip foundation and ground-improvement piles supporting a concrete frame, within which 3D-printed walls—created using a custom COBOD printer—are integrated. This marks a significant milestone as it demonstrates that 3D-printed reinforced concrete can transition from experimental projects to mainstream residential construction in an earthquake-prone country. The O House’s design draws inspiration from natural cave geometry, incorporating sweeping curves and structural arches that serve as integral load-bearing elements rather than mere decoration. The structure rises from half a meter below ground to seven meters above, showcasing vertical printing capabilities beyond single-story prototypes. Construction was completed by a four-person crew working primarily on-site
robotics3D-printingconstruction-technologyearthquake-resistant-designautomated-constructionreinforced-concreteadditive-manufacturingRobotic 3D printing builds 6-meter open-water catamaran in one piece
V2 Group (Spain) and Caracol AM (Italy) have collaboratively developed the first functional 6-meter-long monolithic catamaran for open-water use, fabricated entirely through robotic large-format 3D printing. Unlike traditional boatbuilding, which relies on molds and extensive manual labor, this project produced the hull as a single-piece structure, minimizing joints and assembly steps to enhance structural integrity and streamline production. The initiative focused not only on creating a prototype but also on analyzing the full naval-grade manufacturing workflow—including design, material selection, printing optimization, post-processing, and testing—with scalability, sustainability, and economic efficiency as core objectives. The catamaran was engineered to meet real marine conditions, emphasizing buoyancy, rigidity, and durability, marking a significant step toward industrial-scale additive manufacturing in the nautical sector. The use of robotic extrusion systems allows for highly customizable designs, efficient material use, and reduced environmental impact compared to conventional composite methods. This digital-first approach enables rapid design iterations without new tooling,
robotics3D-printingadditive-manufacturingmarine-technologymaterials-engineeringsustainable-manufacturingindustrial-automationUrsa Major unveils hypersonic missile for air, sea and land launch
U.S. hypersonic propulsion company Ursa Major unveiled the HAVOC Missile System on February 24, a new hypersonic missile designed for rapid, large-scale production to provide faster and more affordable high-speed weapons. Announced at the Air and Space Forces Association Air Warfare Symposium, HAVOC serves a dual role as both a combat weapon and a hypersonic target for testing and training, supporting urgent operational needs while bolstering the U.S. industrial base. Central to the system is Ursa Major’s Draper liquid rocket engine, which uses storable propellants and additive manufacturing to reduce costs significantly compared to traditional air-breathing hypersonic engines. The missile is engineered for mass production and rapid delivery, emphasizing affordability and scalability alongside high performance. A key innovation of HAVOC is its throttleable and restartable engine across all flight phases—boost, cruise, and terminal—enabling advanced maneuverability and mission flexibility beyond conventional hypersonic boost-glide or cruise missiles
materialsenergyadditive-manufacturinghypersonic-propulsionrocket-enginemissile-technologyaerospace-materialsL3Harris cuts hypersonic propulsion component build time tenfold
L3Harris Technologies, a US defense firm, has significantly advanced additive manufacturing for air-breathing hypersonic propulsion systems, achieving a tenfold reduction in component production time. This progress supports the GAMMA-H initiative, which aims to develop scalable, cost-effective manufacturing solutions for hypersonic propulsion. By leveraging large-envelope metal 3D printers and powdered metal feedstock, L3Harris can produce complex high-temperature components—such as scramjet engines made from nickel-based superalloys—with integrated cooling channels and lattice structures that are difficult to manufacture conventionally. The company employs robotic handling, autonomous build monitoring, and in-situ sensors to enhance print quality, reduce defects, and minimize post-processing. The streamlined process consolidates multiple subcomponents into single printed assemblies, cutting down part counts, fasteners, welds, and machining steps, thereby lowering costs and increasing production rates. This effort builds on L3Harris’s hypersonic heritage and is supported by a $22
additive-manufacturinghypersonic-propulsion3D-printinghigh-temperature-materialsnickel-based-superalloysrobotic-handling-systemsaerospace-materialsMaterials scientist Leonard Siebert on 3D printing for medicine
Leonard Siebert, a materials scientist at Kiel University and visiting researcher at KU Leuven, is pioneering innovations in advanced manufacturing with a focus on 3D printing for medicine. He developed Laser-Assisted Melt Printing (LAMP), a novel technique that allows direct 3D printing of glass without the need for lengthy furnace sintering processes, significantly accelerating production and improving energy efficiency. Additionally, as a Marie Curie Postdoctoral Fellow leading the DRUG-SPIN project, Siebert applies melt-spinning methods to enhance the solubility of poorly soluble drugs, aiming to reduce pharmaceutical waste and improve drug delivery. Siebert’s interdisciplinary career bridges materials science, additive manufacturing, and biomedicine. His early exposure to 3D printing during his Ph.D. and collaborative work with medical professionals shaped his approach to translating materials research into clinical applications. A formative research stint at Harvard broadened his expertise in biomedical techniques and reinforced his focus on interdisciplinary collaboration. His work exemplifies how combining physics, chemistry,
materials-science3D-printingadditive-manufacturingmedical-materialsdrug-solubilityadvanced-manufacturingpharmaceutical-technologyUS advanced nuclear reactors near deployment with new fuel deal
The Department of Energy’s Oak Ridge National Laboratory (ORNL) and Kairos Power have initiated a $27 million strategic partnership to accelerate the deployment of advanced nuclear reactors, focusing on the fluoride salt-cooled high-temperature reactor (KP-FHR). This innovative reactor design replaces traditional water coolant with molten fluoride salt, enabling operation at higher temperatures with enhanced inherent safety. Central to the technology are TRISO fuel pebbles, which are highly heat-resistant particles. The collaboration addresses critical technical challenges such as fuel manufacturing, component production via additive manufacturing, material performance under corrosive high-temperature conditions, and the development of remote maintenance systems suitable for radiation environments. These efforts support the Hermes 1 demonstration reactor in Oak Ridge, the first non-light-water reactor approved for construction by the US Nuclear Regulatory Commission, with construction having started in May 2025. In addition to technological development, Kairos Power secured a deal with the DOE to obtain High-Assay Low-Enriched Uranium (HALEU), essential for
energynuclear-reactorsadvanced-nuclear-technologymolten-salt-reactorTRISO-fueladditive-manufacturingenergy-innovationFreeform raises $67M Series B to scale up laser AI manufacturing
Freeform, a company specializing in laser-based metal 3D printing, has raised $67 million in a Series B funding round led by investors including Apandion, AE Ventures, Founders Fund, Linse Capital, Nvidia’s NVentures, Threshold Ventures, and Two Sigma Ventures. The company’s post-financing valuation is reported by Pitchbook to be $179 million. Founded in 2018 by former SpaceX engineers Erik Palitsch and Thomas Ronacher, Freeform aims to revolutionize metal manufacturing by building a highly scalable, AI-native platform that uses advanced software controls and real-time physics-based simulations to improve production quality and throughput. Freeform’s current GoldenEye system employs 18 lasers to fuse metal powders into precision components, but the new Skyfall platform will scale this up dramatically by using hundreds of lasers to produce thousands of kilograms of metal parts daily. The company emphasizes its unique integration of high-performance computing, including on-site H200 GPU clusters, to continuously optimize the manufacturing process
materialsadditive-manufacturinglaser-technologyAI-in-manufacturingmetal-3D-printingindustrial-automationmanufacturing-innovationUS firms unveil autonomous strike aircraft developed at record speed
U.S. defense technology firms Divergent Technologies and Mach Industries unveiled an autonomous strike aircraft prototype named Venom in Los Angeles on February 17, achieving flight readiness in a record 71 days. This rapid development timeline highlights the potential of digital manufacturing and modular engineering to drastically shorten traditional aerospace production cycles, which typically take years. Venom serves as a flight demonstration platform to prove that defense hardware can be designed and produced quickly using software-driven engineering and advanced additive manufacturing techniques. Central to Venom’s accelerated development is Divergent’s Adaptive Production System (DAPS), which replaces complex multi-part assemblies with large, unified structures created through additive manufacturing. This innovation reduces part counts, assembly time, and potential failure points while maintaining structural integrity, enabling aerospace-grade production at speeds comparable to software development. Meanwhile, Mach Industries led the modular system architecture and avionics integration, employing a parallel engineering approach that allowed simultaneous hardware and software development. This method facilitated rapid iteration, testing, and integration of autonomous flight capabilities, further
robotautonomous-aircraftadditive-manufacturingmodular-systemsdigital-manufacturingaerospace-technologyrapid-prototypingNew additive helps solar cells retain 93% power-conversion efficiency
Researchers at Penn State University have discovered that adding the chemical additive 9,10-phenanthrenequinone (PQ) significantly enhances the stability and efficiency of organic solar cells, potentially making them viable for large-scale manufacturing and deployment. Unlike traditional silicon solar panels, which require energy-intensive production and toxic chemicals, organic photovoltaics are more environmentally friendly but typically suffer from short lifespans and rapid efficiency degradation. The study, led by Assistant Professor Nutifafa Doumon and doctoral candidate Souk Yoon “John” Kim, demonstrated that PQ, a low-cost and safer hydrocarbon derivative, helps organic solar cells retain over 93% of their original power conversion efficiency after 180 hours of sustained heat exposure—substantially outperforming commonly used toxic additives that retain only about 76%. The research involved testing organic cells with various structures and additives under different environmental conditions to assess longevity, resilience, and efficiency. PQ was incorporated into the active layer of the cells, which absorbs sunlight, resulting in
energysolar-cellsorganic-photovoltaicsmaterials-scienceadditive-manufacturingpower-conversion-efficiencysustainable-energyChina's new 3d printing method fabricates objects in just 0.6 seconds
A research team at Tsinghua University in China has developed a groundbreaking 3D printing technique called Digital Incoherent Synthesis of Holographic light fields (DISH), which can fabricate complex millimeter-scale objects in just 0.6 seconds. Unlike traditional 3D printing methods that build objects layer-by-layer or point-by-point, DISH uses high-dimensional holographic light fields to simultaneously sculpt entire 3D structures within a resin container. This approach eliminates the need for moving parts or layer drying, achieving a high resolution of 12 micrometers—about one-fifth the thickness of a human hair—across a 1 cm depth range, far surpassing conventional lens depth-of-field limits. The DISH method employs a high-speed rotating periscope to project light from multiple angles and iterative hologram optimization, enabling ultra-fast volumetric additive manufacturing with a printing rate of 333 cubic millimeters per second. The technology works effectively with low-viscosity acryl
3D-printingadditive-manufacturingholographic-light-fieldsvolumetric-printingmaterials-sciencemicro-roboticsflexible-electronicsWorld’s 1st 3D-printed hypersonic platform clears key vibration trials
Queensland-based Hypersonix Launch Systems has successfully completed vibration testing on its DART AE hypersonic technology demonstrator, validating the vehicle’s structural reliability and component integrity ahead of planned flight tests. The DART AE is notable as the world’s first hypersonic launch platform with a fully 3D-printed airframe made from high-temperature alloys. Powered by a hydrogen-fueled scramjet, the single-use demonstrator can reach speeds up to Mach 7, has a length of approximately 3 meters, a mass near 300 kg, and a range of up to 1,000 km. The use of hydrogen fuel offers high thrust and clean-burning advantages, aligning with Hypersonix’s scramjet development efforts. The vibration tests simulated the intense mechanical stresses experienced during launch and high-speed flight, confirming that the DART AE’s materials and components can withstand these conditions. This milestone paves the way for the next phases of integration and pre-flight preparations. Hyperson
energymaterialsadditive-manufacturinghypersonic-technologyhydrogen-fuelhigh-temperature-alloysaerospace-engineering3D-printed nuclear batteries could power long-duration space, defense missions
South Australian engineering firm entX, in collaboration with the University of Adelaide, is developing GenX, a 3D-printed nuclear battery designed to provide long-duration, maintenance-free power for space, defense, and remote missions. Unlike traditional bulky nuclear generators that use heat from plutonium decay, GenX employs betavoltaics—ultra-thin, additively manufactured devices that stack nanoscale layers of metals and semiconductors to achieve unprecedented power densities in a compact, durable form. This innovative approach represents a significant advancement over conventional batteries, enabling energy solutions where solar power and refueling are impractical, such as deep ocean drones or remote sensors. The project, supported by a $1.8 million investment and the Additive Manufacturing Cooperative Research Centre, aims to transition GenX from a laboratory prototype to commercial production within 14 months. Custom 3D-printed radiation shields will ensure safe deployment in satellites, submersibles, and other platforms. The technology promises to unlock new
energynuclear-batteries3D-printingadditive-manufacturingbetavoltaicsspace-technologylong-duration-power-sourcesLaser-assisted 3D printing method forms ultra-hard tungsten carbide
A Japanese research team has developed a novel laser-assisted additive manufacturing method to produce industrial-grade tungsten carbide–cobalt (WC–Co) cemented carbides, materials essential for cutting tools and heavy-duty equipment due to their extreme hardness and wear resistance. Traditional powder metallurgy techniques for shaping WC–Co are costly and wasteful, requiring high pressure, elevated temperatures, and sintering, which limit design flexibility and result in significant material loss. The new approach employs hot-wire laser irradiation, combining a laser beam with a preheated filler wire to deposit material precisely where needed, reducing waste and production costs while preserving the material’s hardness and microstructure by avoiding full melting. The researchers tested two deposition strategies—advancing the carbide rod ahead of the laser and allowing the laser to lead while irradiating the gap between the rod and an iron base. Both methods softened rather than melted the material to enable bonding, minimizing thermal damage. The resulting cemented carbide achieved hardness exceeding 1400 HV, comparable to the hardest
materialsadditive-manufacturingtungsten-carbidelaser-assisted-3D-printingcemented-carbidesindustrial-manufacturingwear-resistant-materialsUS Marine sergeant builds 3D-printed attack drone under $700 apiece
The U.S. Marine Corps has developed HANX, its first in-house 3D-printed drone that complies with the National Defense Authorization Act (NDAA) by excluding parts from designated foreign adversaries like China. Created by Sgt. Henry David Volpe and the 2nd Marine Logistics Group, HANX is a modular unmanned aerial system designed to support multiple battlefield roles such as reconnaissance, logistics, and one-way attack missions. The drone can carry up to a one-kilogram payload and is produced using additive manufacturing techniques, allowing Marines to build, repair, and modify it internally. At approximately $700 per unit, HANX is significantly more affordable than comparable military drones, which often cost up to $4,000 each. Its modular design also enables customization to meet specific mission needs while maintaining strict cybersecurity and supply chain controls. The development of HANX aligns with the Department of Defense’s “Drone Dominance” initiative, which aims to acquire 300,000 one-way attack
robot3D-printingdronesunmanned-aerial-systemsmilitary-technologyadditive-manufacturingsupply-chain-securityMIT turns recycled plastic into structural trusses that beat US housing load tests
Engineers at MIT have developed a method to convert recycled plastic waste into high-strength structural floor trusses using large-scale 3D printing. These trusses, made from recycled PET polymer pellets reinforced with glass fibers, demonstrated exceptional durability by supporting 4,000 pounds—double the load requirements set by U.S. federal housing standards. The lightweight trusses, weighing only 13 pounds each compared to heavier timber counterparts, were produced rapidly, with each truss printed in under 13 minutes. The design incorporates a traditional ladder and triangle wood truss pattern enhanced with reinforced joints for added stability, ensuring rigidity and load-bearing capacity comparable to conventional materials. The MIT team, led by researcher AJ Perez, aims to address the global housing crisis sustainably by replacing wood and concrete—both environmentally problematic materials—with recycled plastic. They highlight the environmental impact of traditional construction, noting that meeting future housing demands with wood alone would require deforestation on an unprecedented scale. Currently, the prototypes use high-quality factory plastic waste,
materialsrecycled-plastic3D-printingstructural-trussessustainable-constructionadditive-manufacturingMIT-engineeringToyota Uses bZ Time Attack Concept to Probe the Limits of EV Racing - CleanTechnica
At the 2025 SEMA Show, Toyota unveiled the bZ Time Attack Concept, a battery-electric vehicle (BEV) prototype designed to explore the limits of electric motorsport performance rather than serve as a styling exercise or competition entry. Built on the forthcoming 2026 all-wheel-drive bZ platform, the concept delivers over 400 horsepower through recalibrated dual motors, emphasizing short-duration power output for racing conditions like time attack and hill climbs. The vehicle features significant modifications from production EVs, including a lowered ride height by six inches, a widened track, a reinforced chassis with an FIA-spec roll cage, and adapted suspension and braking components from Toyota’s circuit racing programs. A key focus of the project was addressing the complex aerodynamic and thermal management challenges unique to EVs, balancing cooling requirements for batteries and motors with drag reduction. Toyota employed advanced techniques such as laser scanning, CAD modeling, and large-scale 3D printing to develop a bespoke widebody aero package, including fender extensions
energyelectric-vehiclesbattery-technologymotorsport-engineeringadditive-manufacturingaerodynamicsthermal-managementUS scientists develop 3D printing method that could reshape body armor
Researchers at The University of Texas at Austin and Sandia National Laboratories have developed a novel 3D printing technique called Crystallinity Regulation in Additive Fabrication of Thermoplastics (CRAFT). This method enables the creation of 3D objects with varying mechanical and optical properties—such as hardness and transparency—at the pixel level using a single, inexpensive material, cyclooctene resin. By precisely controlling light intensity during printing, the team can manipulate the molecular order of the material as it solidifies, allowing different parts of an object to have distinct textures and properties within a single piece. For example, they successfully printed a realistic human hand model that mimics the textures of skin, ligaments, tendons, and bone, offering a superior alternative to cadavers for medical training. CRAFT’s ability to produce seamless transitions between hard and soft regions addresses a common limitation in existing multi-material 3D printing, which often suffers from weak bonding at joints. Beyond medical applications, the technique
materials3D-printingadditive-manufacturingbody-armorthermoplasticsbioinspired-materialsmechanical-properties3D printing breakthrough merges multiple materials in one print
Researchers at Oak Ridge National Laboratory (ORNL) have developed a novel extrusion system for large-scale 3D printing that merges multiple smaller extruders into a single high-output material stream using specially engineered nozzles. This innovation overcomes a key tradeoff in extrusion-based additive manufacturing: large extruders provide high volume but reduce precision and add weight, while smaller extruders offer control but lack scalability. ORNL’s modular system allows users to activate or deactivate extruders as needed, scaling output without sacrificing accuracy or increasing the mechanical burden on motion systems. A standout feature of the technology is its ability to print multiple materials simultaneously within a single extrusion bead, eliminating the need for tool changes or separate print passes. This is achieved through patent-pending aluminum bronze nozzle blocks with Y-shaped internal channels that merge molten polymer streams, improving bead quality and doubling material flow. Additionally, a proprietary nozzle design enables core-and-sheath bead structures, combining different polymers to enhance mechanical properties and interlayer adhesion, addressing common
3D-printingadditive-manufacturingmulti-material-extrusionmaterials-engineeringpolymer-compositesmanufacturing-technologyOak-Ridge-National-LaboratoryUK-made super materials to shield fusion reactors from extreme heat
The UK has made a significant advancement toward its goal of operating a prototype fusion power plant by 2040 through the launch of DIADEM, a research initiative focused on overcoming a major materials engineering challenge. Fusion reactors require components that can withstand extreme heat—up to 3,000°C—and intense magnetic fields. Tungsten and copper are ideal materials for these conditions due to tungsten’s high melting point and copper’s excellent heat conduction. However, their vastly different melting points and thermal expansion rates have made traditional joining methods like welding or casting ineffective, often resulting in cracks or separation. DIADEM, led by the University of Nottingham’s Centre for Additive Manufacturing, is addressing this by using Multi-Metal Laser Powder Bed Fusion (MM-LPBF), an advanced 3D printing technique that simultaneously fabricates tungsten-copper components from the ground up. This process creates “metamaterials” with a smooth microscopic transition between the two metals, eliminating weak seams and improving durability. This breakthrough not only advances
materialsfusion-energyadditive-manufacturingmetamaterialstungstencopper3D-printingIndian SpaceX rival EtherealX hits 5x valuation as it readies engine tests
Ethereal Exploration Guild (EtherealX), an Indian space technology startup, has seen its valuation surge 5.5 times to $80.5 million following a $20.5 million oversubscribed Series A funding round led by TDK Ventures and BIG Capital. The Bengaluru-based company is developing a fully reusable launch vehicle designed to return both the booster and upper stage, aiming to reduce launch costs and increase flight frequency. EtherealX plans to conduct hot-fire tests of its two in-house developed engines—the 80-kilonewton Pegasus upper-stage engine and the 1.2-meganewton Stallion booster engine—in June–July 2026, with a technology demonstration flight targeted for late 2027 and commercial missions expected by the end of 2028. The startup’s medium-lift vehicle, Razor Crest Mk-1, will cluster multiple engines per stage (nine Stallion engines on the booster and 15 Pegasus engines on the upper stage) and aims
energyrocket-enginesspace-technologyreusable-launch-vehicleadditive-manufacturingpropulsion-systemsaerospace-materialsNew 3D-printed smart material lets ceramics bend to survive heavy loads
Researchers at Virginia Tech have developed a novel 3D-printed smart composite that enables traditionally brittle ceramics to bend, absorb energy, and endure heavy mechanical loads without cracking. Led by Associate Professor Hang Yu, the team embedded tiny shape-memory ceramic particles into metal using a solid-state additive friction stir deposition (AFSC) process, which fuses materials below their melting point under intense pressure. This approach produces a strong, defect-free composite that can undergo stress-induced phase transformations to dissipate energy, allowing the material to withstand tension, bending, and compression while maintaining full density in bulk form. This breakthrough overcomes a longstanding challenge in materials science, as shape-memory ceramics previously only functioned at microscopic scales due to their tendency to fracture when produced in bulk. The new composite’s multifunctionality and scalability open up promising applications across defense, aerospace, infrastructure, and high-performance sporting equipment, such as vibration damping in golf club shafts. Supported by the National Science Foundation and the US Army Research Laboratory, the research highlights
materials-science3D-printingsmart-materialsceramicscomposite-materialsadditive-manufacturingshape-memory-materialsWorld’s first software-defined fuselage to boost fighter jet agility
Swedish aerospace company Saab, in partnership with Divergent Technologies, has developed the world’s first software-defined aircraft fuselage, marking a significant advancement in fighter jet design and manufacturing. This experimental fuselage, over five meters long and composed of 26 unique 3D-printed metal parts, was produced using large-scale metal additive manufacturing combined with software-driven production techniques. Notably, no traditional tooling or fixtures were needed, making it one of the largest additively manufactured metal structures prepared for powered flight. Having passed structural proof-loading tests, the fuselage is slated for flight testing in 2026. This innovation aligns with Saab’s strategic move toward model-based engineering (MBE), which uses shared digital twins and 3D digital instructions to streamline design, simulation, and system optimization, as demonstrated in the Gripen E fighter program. Saab’s internal innovation team, The Rainforest, is pushing the concept further by exploring “Software-Defined Hardware Manufacturing,” aiming to bring the same software
roboticsadditive-manufacturingsoftware-defined-hardwaredigital-twinaerospace-engineeringindustrial-automation3D-printing-materialsUS firm tests solid rocket motor, propulsion tech for target vehicles
Northrop Grumman, a Virginia-based US firm, has successfully tested the first of two new solid rocket motors—SMASH!22 and BAMM!29 2.0—under its Solid Motor Annual Rocket Technology Demonstrator (SMART Demo) program. The SMASH!22, a 22-inch diameter motor, underwent a static test fire that incorporated advanced manufacturing techniques, new materials, and innovative processes aimed at speeding development, improving performance, and reducing costs. This test generated extensive data to enhance understanding of these novel technologies, which are the first of their kind in the solid rocket motor industry. The SMART Demo program is an annual initiative designed to develop, build, and test new solid rocket motors and associated tooling, focusing on technologies such as complex additively manufactured components and alternative manufacturing materials. The second motor, BAMM!29 2.0, a 29-inch diameter Bombardment Attack Missile Motor, is scheduled for static testing in early 2026. Northrop
energysolid-rocket-motorpropulsion-technologyadvanced-manufacturingadditive-manufacturingmaterials-scienceaerospace-engineeringUS seeks inspiration from nature for next-gen nuclear fuel design
Scientists at Idaho National Laboratory (INL) are pioneering a novel approach to nuclear fuel design by drawing inspiration from nature’s mathematics, specifically triply periodic minimal surfaces (TPMS). These complex, repeating lattice structures, found naturally in butterfly wings and sea urchin shells, offer highly efficient geometries that can enhance heat transfer in nuclear fuel. INL’s concept, called the Intertwined Nuclear Fuel Lattice for Uprated heat eXchange (INFLUX), replaces traditional solid cylindrical fuel rods with a TPMS-based lattice. This design increases surface area contact with coolant, enabling more efficient heat removal and potentially leading to safer, more compact, and higher-performing nuclear reactors. Recent laboratory tests involving 3D-printed electrically conductive models of the INFLUX lattice demonstrated that the TPMS geometry transfers heat about three times more efficiently than conventional fuel rods. This improvement could allow for thinner fuel, lower operating temperatures, and reduced thermal stress, enhancing reactor performance and economics. Manufacturing challenges remain due
energynuclear-fueladditive-manufacturingheat-transfertriply-periodic-minimal-surfacesreactor-technologymaterials-scienceUS develops 3D-printed concrete substitute for rapid construction
Researchers at Oregon State University have developed a sustainable, clay-based 3D-printable construction material designed to address both environmental and speed challenges in building. Traditional cement production is a major contributor to global CO2 emissions and requires a lengthy curing time of up to 28 days. The new material uses frontal polymerization with an acrylamide-based binder, allowing it to cure instantly as it is printed. This rapid curing enables the construction of multilayer walls and freestanding structures immediately, reaching residential concrete strength (over 17 megapascals) within three days—significantly faster than conventional concrete. The eco-friendly composite is made primarily from soil, hemp fibers, sand, and biochar, a carbon-rich byproduct that helps sequester carbon, thereby reducing the carbon footprint compared to traditional cement. This innovation is particularly promising for rapid shelter construction in disaster-stricken areas, where speed and sustainability are critical. While current costs are higher than standard concrete, the research team aims to reduce expenses and
materials3D-printingsustainable-constructionconcrete-substituterapid-curingbiocharadditive-manufacturingLight, extremely strong material withstands 932°F temperature, could be useful for aerospace
Researchers at the University of Toronto Engineering have developed a novel lightweight and extremely strong metal matrix composite capable of withstanding temperatures up to 932°F (500°C), making it highly promising for aerospace and other high-performance applications. The material mimics the structure of reinforced concrete on a microscopic scale, featuring a titanium alloy mesh acting as "rebar" surrounded by a matrix composed of aluminum, silicon, magnesium, and embedded alumina and silicon nanoprecipitates. This design, enabled by additive manufacturing and micro-casting techniques, allows precise control over the composite’s microstructure, resulting in exceptional strength and thermal resistance. Testing revealed that the composite exhibits a yield strength of around 700 megapascals at room temperature—significantly higher than typical aluminum matrices—and maintains 300 to 400 megapascals at 500°C, compared to just 5 megapascals for conventional aluminum alloys. This performance rivals medium-range steels but at roughly one-third the weight, addressing a critical limitation of aluminum alloys
materialscomposite-materialsaerospace-materialsmetal-matrix-compositeadditive-manufacturinghigh-temperature-materialslightweight-materialsInside the robot-powered factory, printing the furniture of tomorrow
The article explores a futuristic vision of furniture manufacturing driven by AI-powered robots and advanced digital technologies, transforming traditional woodworking into a highly efficient, sustainable process. Central to this innovation is Haddy’s micro factory, which employs industrial-scale 3D printing to produce furniture with zero waste by using only the material necessary for each piece. This factory, equipped with eight CEAD hybrid Flexbots, can produce 300,000 customized items annually in a modular, replicable setup that could be implemented globally, redefining both production scale and location. Siemens contributes critical digital intelligence through its Digital Twin technology, allowing engineers to create detailed virtual replicas of furniture designs that can be tested and optimized before physical production. This virtual-to-physical workflow, facilitated by Siemens NX software, eliminates costly prototyping and guides the robots’ precise movements. CEAD’s Flexbots perform both additive and subtractive manufacturing tasks with real-time sensor feedback, enabling adaptive adjustments to maintain quality and efficiency. The system continuously learns from operational data,
robot3D-printingdigital-twinmanufacturing-automationindustrial-robotssustainable-productionadditive-manufacturingChina’s first 3D-printed mini turbojet engine hits Mach 0.75 in tests
China’s state-owned Aero Engine Corporation of China (AECC) has successfully tested its first fully 3D-printed miniature turbojet engine in a solo flight, marking a significant milestone in the country’s independent aviation propulsion development. The ultra-lightweight engine, producing 353 pounds of thrust, powered a target drone to an altitude of 6,000 meters (about 20,000 feet) and reached speeds of Mach 0.75 during a 30-minute flight. The engine operated stably throughout, validating its design, reliability at higher altitudes, and integration with aircraft systems. This test follows an earlier captive-carry flight at 4,000 meters and represents a transition from controlled testing to operational application. The engine’s design leverages a combination of 3D printing and multi-disciplinary topology optimization (TO), a computational method that optimizes material distribution for performance and weight reduction. This approach enables the creation of complex, lightweight structures that traditional manufacturing cannot easily produce. Over three-
3D-printingadditive-manufacturingturbojet-engineaerospace-materialstopology-optimizationlightweight-materialsaviation-technologyUS to 3D-print vital weapon parts in its closest territory to China
The US territory of Guam has initiated the construction of its first advanced manufacturing facility, the Guam Advanced Material & Manufacturing Accelerator (GAMMA), aimed at producing vital 3D-printed parts for US Navy submarines and commercial industries across Asia. Led by the nonprofit ASTRO America, GAMMA will house state-of-the-art equipment for just-in-time manufacturing, potentially reducing supply delays for military and civilian users. This development marks Guam’s entry into the US defense manufacturing supply chain and is expected to begin producing submarine parts by the end of next year. The project is part of a five-year collaboration between the Government of Guam and the US Navy, designed to enhance defense readiness and diversify Guam’s economy beyond tourism. Central to this initiative is a partnership involving the University of Guam (UOG), ASTRO America, and the Colorado School of Mines to establish a 2+2 mechanical engineering degree program, allowing students to earn accredited degrees locally while gaining hands-on experience with additive manufacturing. The university also plans
3D-printingadvanced-manufacturingdefense-technologymaterials-scienceadditive-manufacturingsupply-chain-innovationaerospace-manufacturingThis startup’s metal stacks could help solve AI’s massive heat problem
The article discusses Alloy Enterprises, a startup addressing the escalating cooling challenges posed by increasingly power-hungry AI data center racks. Nvidia recently revealed that future GPU racks, expected in 2027, could consume up to 600 kilowatts of electricity—nearly double the capacity of some fast EV chargers. This surge in power density creates significant heat dissipation issues, especially for peripheral chips like memory and networking hardware, which account for about 20% of a server’s cooling load but currently lack effective cooling solutions. Alloy Enterprises has developed a novel cooling technology using stacks of copper sheets bonded through a process called diffusion bonding or "stack forging," producing seamless, solid metal cold plates that can fit into tight spaces and withstand high liquid cooling pressures. Unlike conventional machined cold plates, which are assembled from separate halves and prone to leaks at seams, Alloy’s stack forging method creates single-block copper plates with no seams and superior structural integrity. This process also allows for finer features—down to 50 mic
energymaterialscooling-technologyadditive-manufacturingmetal-bondingdata-centersthermal-managementProgrammable materials create multistable motor-less finger for robotics
Researchers at the Fraunhofer Cluster of Excellence Programmable Materials (CPM) have developed a novel finger joint made from a single piece of programmable metamaterial, called the ProFi (Programmable Multistable Finger) project. This motor-less finger can lock into four stable positions without the need for screws, hinges, or multiple interconnected parts, simplifying the design of hand prostheses and robotic grippers. The finger bends along one axis in 30-degree increments, enabling distinct gripping, resting, or gesturing positions. The design was validated through finite element method simulations to ensure durability and stiffness, and was produced using additive manufacturing techniques like Fused Deposition Modeling and Selective Laser Sintering, allowing for easier customization and assembly-free fabrication. The key innovation lies in the integration of bistable unit cells—elastic beams that snap between stable states without continuous force—within the joint’s internal structure. Using specialized software (ProgMatCode), researchers optimized these cells to create a passive multistable mechanism
programmable-materialsroboticsprostheticsmetamaterials3D-printingmultistable-structuresadditive-manufacturingNew 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: Vittori unveils AI-assisted hypercar with 1,100 horsepower
Vittori, a new performance brand founded by entrepreneur Carlos Cruz, has unveiled its debut hypercar, the Turbio, at The Concours Club in Miami. Limited to just 50 units, the Turbio combines Italian craftsmanship with American ambition, featuring a proprietary hybrid powertrain that pairs a 6.8-liter V12 engine with a front-axle electric motor to deliver a combined 1,100 horsepower. The car incorporates AI-assisted design, additive manufacturing, and race-inspired engineering, with advanced aerodynamics including an adaptive rear wing that optimizes drag and downforce for enhanced stability and cornering. The Turbio’s interior emphasizes driver engagement through tactile controls and mechanical switches, diverging from the touchscreen-heavy cabins common in modern supercars. The vehicle’s design was developed in collaboration with Pininfarina, the renowned Italian design house known for its legacy of automotive excellence and innovation. Vittori aims to create a hypercar that blends performance, beauty, and control without compromise, positioning
energyhybrid-technologyAI-assisted-designadditive-manufacturingautomotive-engineeringaerodynamicselectric-motorAirbus 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-aviationUS 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-materialsArgonne 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-fusion4D printing with smart materials is changing product design
The article discusses the transformative impact of 4D printing, an advancement over traditional 3D printing that incorporates smart materials capable of changing shape, properties, or functionality over time in response to external stimuli such as temperature, light, moisture, or pH. Originating from the concept introduced by MIT researchers in 2013, 4D printing uses programmable materials that enable printed objects to bend, fold, expand, or contract after fabrication, effectively adding time as a functional design dimension. This innovation allows objects to adapt to their environment or self-assemble, marking a significant evolution in additive manufacturing. Key applications of 4D printing span across multiple industries. In medicine, it enables devices like stents that can expand automatically inside the body, reducing invasive procedures, and drug delivery systems that release medication only under specific conditions, enhancing treatment safety and efficacy. In construction and aerospace, 4D printing promises self-assembling structures that reduce labor and costs, while in robotics, it facilitates the creation
4D-printingsmart-materialsadditive-manufacturingshape-memory-polymersprogrammable-materialsadaptive-materialsmaterials-science4D printing with smart materials is changing product design
The article discusses the transformative impact of 4D printing, an advancement of traditional 3D printing that incorporates smart materials capable of changing shape, properties, or functionality over time in response to external stimuli such as temperature, light, moisture, or pH. This innovation adds the dimension of time to additive manufacturing, enabling printed objects to bend, fold, stretch, or self-assemble after fabrication. Originating from concepts introduced by MIT researchers in 2013, 4D printing leverages programmable materials like shape memory polymers to create dynamic structures, such as medical stents that expand at body temperature or flat structures that morph into complex shapes when triggered. The potential applications of 4D printing span multiple industries. In medicine, it offers minimally invasive devices and targeted drug delivery systems that activate under specific conditions, enhancing treatment safety and efficacy. In construction and aerospace, 4D printing could facilitate self-assembling structures, reducing labor and costs. Additionally, the technology promises advancements in soft robotics and
4D-printingsmart-materialsadditive-manufacturingshape-memory-polymersprogrammable-materialsadaptive-materialsmaterials-science14-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-manufacturingUS firm's rocket engine that delivers 4,000-lb thrust to get upgrade
A Colorado-based company, Ursa Major, is advancing its Draper rocket engine, designed for space-based defense and hypersonic applications, following a $34.9 million contract from an undisclosed U.S. aerospace and defense firm. The Draper engine operates on non-cryogenic, non-toxic propellants and combines the storability of solid rocket motors with the higher performance, restart capability, throttle control, and maneuverability of liquid engines. This makes it suitable for rapid response and in-space maneuverability, addressing critical national security needs by providing enhanced responsiveness and flexibility against emerging threats in space and missile defense. Draper is notable for its affordable production, leveraging additive manufacturing with nearly two-thirds of its components made in the U.S., and a design that supports storage for at least 10 years. It has been hot-fired over 250 times, demonstrating safety, reusability, and reliability. The engine’s active throttle control allows it to simulate hypersonic threats more effectively than
energyrocket-enginepropulsionhypersonic-defenseadditive-manufacturingspace-technologystorable-propellantsLeak-proof ceramic 3D printing paves way for next-gen reactors
Scientists at Oak Ridge National Laboratory (ORNL) have made a significant breakthrough in ceramic additive manufacturing by developing a method to produce leak-tight ceramic components using binder jet additive manufacturing (BJAM) combined with advanced post-processing. This innovation overcomes a major hurdle in scaling ceramic 3D printing for high-performance applications, enabling the creation of larger, complex, and gas-tight ceramic parts that were previously difficult to manufacture. The team demonstrated this by printing components filled with a silicon-carbide pre-ceramic polymer and heat-treating them to form amorphous silicon carbide, achieving the first known leak-tight joint fabricated via additive manufacturing. This advancement not only enhances the fabrication of intricate, resilient ceramic parts ideal for extreme environments—such as those found in pharmaceuticals, chemical processing, aerospace, and clean energy—but also offers economic benefits. BJAM is a cost-effective, faster method compared to other ceramic 3D printing techniques, and ORNL’s joining method allows industries to consider ceramics for broader high-performance
materialsceramic-3D-printingadditive-manufacturingleak-proof-ceramicshigh-performance-materialsbinder-jet-additive-manufacturingnext-generation-reactorsBoeing 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-manufacturingBoeingUS' 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-printingStronger 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-materialsUS firm's solid rocket motor with grain propellant tech tested
Colorado-based Ursa Major successfully conducted static fire tests of an upgraded solid rocket motor featuring its Highly Loaded Grain (HLG) propellant technology, which delivers increased performance and extended range without enlarging the motor’s size. Developed in collaboration with BAE Systems, this extended range variant is designed for the APKWS laser-guidance kit, a combat-proven system that converts unguided 2.75-inch rockets into precision-guided munitions (PGMs) with high accuracy and minimal collateral damage. The successful tests pave the way for a planned flight demonstration in fall 2025. Ursa Major’s next-generation motor incorporates a flexible design architecture compatible with multiple missile systems and integrates with its Lynx Manufacturing System, a software-enabled additive manufacturing line that enhances production speed and scalability. This approach aims to overcome legacy industrial bottlenecks and rapidly provide critical solid rocket motor capacity for the U.S. and allied forces. The APKWS system, qualified on numerous U.S. Department of Defense platforms
energysolid-rocket-motorgrain-propellantmissile-technologyadditive-manufacturingprecision-munitionsaerospace-materialsHeavy 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-technologyNew 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-engineering4th-gen nuclear reactors near US launch as advanced fuel line goes live
BWX Technologies (BWXT) has launched a new production line for Uranium Nitride TRISO fuel at its Lynchburg Technology Center in Virginia, marking a significant step toward supporting Generation IV nuclear reactors. The completion of a chemical vapor infiltration furnace enabled the line to become operational, allowing the facility to produce additively manufactured fuel forms with a higher density of TRISO particles per pellet. TRISO fuel particles feature a uranium core surrounded by carbon and silicon carbide layers designed to contain fission products at extremely high temperatures, enhancing fuel efficiency and potentially reducing reactor system costs. This initiative is part of the U.S. Department of Energy’s Advanced Reactor Demonstration Program (ARDP), which backs BWXT’s BANR high-temperature gas microreactor design. BWXT’s new line focuses on uranium nitride fuel, distinct from its existing uranium oxycarbide TRISO fuel used in the Department of Defense’s Project Pele. The company collaborates with Idaho National Laboratory and Oak Ridge National Laboratory to test
energynuclear-energyadvanced-reactorsTRISO-fueladditive-manufacturingmicroreactorsfuel-efficiencyUS turns cargo containers into nuke bunkers for remote military bases
Sandia National Laboratories has developed a mobile, high-security vault housed within a 20-foot shipping container to safeguard nuclear weapons at remote or temporary military locations where permanent bunkers are not feasible. Created under the National Nuclear Security Administration’s Stockpile Responsiveness Program, the project was completed in six months using a rapid, adaptable design approach. The vault features advanced access control, alarm systems, sensors, and backup power, built with a combination of off-the-shelf parts, rapid prototyping, and additive manufacturing. Two additional prototypes are underway, with upcoming testing planned during the Department of Defense’s Grey Flag 25 exercise to simulate real-world conditions. This mobile vault offers a flexible and scalable solution for secure storage of nuclear weapons and other critical assets in field conditions, providing new capabilities for military and civilian missions. The technology aims to protect sensitive materials during transport or operations in locations lacking traditional infrastructure, such as battlefields or disaster zones. Sandia plans to transition the technology to industry for broader production and deployment
energymaterialssecurity-technologyadditive-manufacturingsensorsrapid-prototypingnuclear-safetyUS 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-engineeringUK 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-materialsUS 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-LaboratoryQatar 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-development3D-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-innovationWorld'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-manufacturingUS turns recycled scrap into 3D-printed rocket parts with AI boost
robotmaterials3D-printingAIadditive-manufacturingrecycled-materialssustainable-manufacturing