#Additive Manufacturing

[materialsscienceandengineering]

Nanomanufacturing process slashes chip production costs by 99%

The current microelectronics manufacturing method is expensive, slow and energy and resource intensive. But a Northeastern University professor has patented a new process and printer that not only can manufacture advanced electronics and chips more efficiently and cheaply, it can make them at the nanoscale. "I thought that there must be an easier way to do this, there must be a cheaper way to do this," says Ahmed A. Busnaina, the William Lincoln Smith professor and a distinguished university professor at Northeastern University. "We started, basically, with very simple physical chemistry with a very simple approach." Busnaina runs the National Science Foundation Center for High-rate Nanomanufacturing at Northeastern University.

Read more.

[balenciaga03]

Reload day

[june-gdprototyping]

Top 8 Applications of 3D Printing in Medical Industry

3D printing technology, with its highly customizable, responsive and material-saving features, is triggering profound changes in the medical field. Especially in the application of medical models, 3D printing technology shows unparalleled advantages and potential.

Furthermore, 3D printing technology, as an emerging additive manufacturing technology, has made breakthroughs in its application in the medical field in recent years. The application of 3D printing technology in the medical field is becoming more and more widespread. Through the layer-by-layer stacking of digital models, a variety of medical devices, prosthetics, orthotics and other aids, and even human organs, can be accurately printed.

1.Surgical preview model

With 3D printing technology, doctors can create surgical preview models to help them simulate operations before surgery, improving accuracy and safety.

It is important for medical workers to conduct preoperative planning for risky and difficult procedures. In the previous surgical preview process, medical workers often need to obtain the patient's data through CT, magnetic resonance imaging (MRI) and other imaging equipment, and then the two-dimensional medical image using software to convert into realistic three-dimensional data. Today, medical workers can use devices such as 3D printers to print 3D models directly. In this way, it not only can assist the doctor to carry out accurate surgical planning, improve the success rate of surgery, but also to facilitate the communication and exchange between medical workers and patients on the surgical program plan.

2.Surgical guide

Surgical guides can help the surgeon to accurately position and operate during surgery, reducing surgical errors and improving surgical outcomes.

As an auxiliary surgical tool during surgery, surgical guides can help medical workers to accurately implement surgical programmes. Currently, the types of surgical guides have included joint guides, spinal guides, oral implant guides, etc. With the help of 3D printed surgical guides, firstly, the 3D scanning technology can produce three-dimensional data on the patient's affected area, which allows the doctor to obtain the most realistic information, so as to better plan the surgery. Secondly, while making up for the shortcomings of the traditional surgical guide manufacturing process, the size and shape of the guide can also be adjusted as needed.In this way, different patients can have a guide plate that meets their real needs.

3.Dental applications

3D printing technology is also widely used in the field of dentistry to print personalized trays, moulds, etc., to help patients have better dental treatment.

The application of 3D printing in the dental field mainly focuses on the design and production of metal teeth, invisible braces, etc. The emergence of cutting-edge technology of 3D printing creates more possibilities for those who need orthodontic treatment to achieve personalized and customized braces. At different stages of orthodontic treatment, orthodontists need different sets of braces. With the help of 3D printing to create multiple sets of braces needed for orthodontic treatment, it not only helps the healthy development of teeth, but also reduces the cost of braces production. The significance of these digital technologies is that they are gradually making it less necessary for doctors to make models, dentures, etc. by hand, and returning more of their efforts to the diagnosis of oral diseases and the performance of oral surgery itself.

4.Rehabilitation medical equipment

Through 3D printing technology, a variety of rehabilitation medical devices, such as prosthetics and orthotics, can be created to help patients regain function.

The real value of 3D printing for orthopaedic insoles, bionic hands, hearing aids and other rehabilitation devices is not only to achieve accurate customization, but also to allow accurate and efficient digital manufacturing technology to replace the traditional production methods, reducing the cost of individual customized rehabilitation medical devices and shortening the production cycle. 3D printing process is diversified, and there is a wide range of 3D printing materials. SLA light-curing 3D printing technology has the advantage of being able to provide the most efficient and cost-effective 3D printing technology. SLA light-curing 3D printing technology is widely used in rapid prototyping by the medical device industry due to its advantages of fast processing speed, high precision, good surface quality of photosensitive resin material moulding and moderate cost.

5.Medical Equipment Cases

3D printing technology can also be used to create a variety of medical devices, such as surgical instruments and medical equipment, to improve the personalization and accuracy of medical devices.

Take the example of 3D printing for mass customized production in the hearing aid shell industry. In the traditional way, injection moulds need to be made from a model of the patient's ear canal. The final shape of the hearing aid is obtained by drilling sound holes and manually processing the plastic product. If a mistake is made during the process, the mould needs to be recreated. The process of making a hearing aid using a 3D printer, on the other hand, begins with the design of a silicone mould or impression of the patient's ear canal, a step that is done using a 3D scanner. CAD software is then used to convert the scanned data into a design file that can be read by the 3D printer. The designer can then use the software to modify the 3D image and create the final product shape.

6.Precision replication and personalization

3D printing technology is able to accurately restore a patient's anatomy and produce full-size, high-fidelity medical models based on the patient's CT, MRI and other imaging data. These models not only have extremely high geometric accuracy and surface quality, but also reflect the unique physiological characteristics of the patient, providing doctors with real and reliable references.

7.Teaching and training

3D printed medical models also play an important role in medical education and training. By printing out models of various typical cases, medical students can perform practical operations in a simulated surgical environment to enhance their surgical skills and resilience. At the same time, these models can also be used as teaching tools to help students better understand human anatomy and disease principles.

8.Scientific research and experimentation

In the field of medical research, 3D printed medical models also have important applications. Researchers can use these models to conduct experimental studies such as drug screening and biomechanical testing to explore new treatment methods and technologies. In addition, by printing tissue or organ models with specific physiological functions, they can also provide strong support for research in cutting-edge fields such as organ transplantation and regenerative medicine.

In summary, 3D printing technology has a wide and far-reaching significance in the application of medical models. It not only improves the accuracy and efficiency of medical services, but also promotes the innovative development of medical education, research and clinical practice. With the continuous progress of technology and the expansion of application scope, we have reason to believe that 3D printing will play a more important role in the future medical field.

[materiallugy]

Additive manufacturing for aerospace part.

Know more about additive manufacturing

[creacompdesign]

The AU project leverages the benefits of additive manufacturing , (AM), computational design and the use of composite materials to drive innovation in the medical and healthcare sector. By integrating these advanced technologies, AU aims to:

Optimize pressure distribution and comfort using personalized pressure mapping data.

Reduce weight, product size, and part count, enhancing ergonomics and usability.

Ensure more effective cooling and breathability.

Extend product longevity, performance, and customizability.

Introduce cutting-edge aesthetics to help combat stigma.

Improve sustainability by prioritizing additive over traditional subtractive manufacturing processes.

For more information, get in touch or check out our submission: 🔗 Link

[3dwithus]

Formnext is happening next week! 🌟 Curious about what to expect? Visit our Formnext Highlights Guide to warm up for the event.

[architecturalthesis]

scene setup

[mastergarryblogs]

How Israeli Tech is Shaping the Future of Additive Manufacturing Worldwide

Overview of Israel’s Strategic Position in Additive Manufacturing

Israel has rapidly emerged as a global force in additive manufacturing (AM), fortified by a powerful high-tech ecosystem, robust government support, and a legacy of innovation in defense, aerospace, and medical technologies. With the Israel additive manufacturing market valued at USD 221.4 billion in 2024 and forecasted to exceed USD 280.3 billion by 2032, the nation is positioned to lead transformative advances in 3D printing technologies. The Israel additive manufacturing market compound annual growth rate (CAGR) of approximately 7% reflects both escalating domestic demand and global interest in Israeli AM innovation.

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Driving Forces of Growth in Israel's Additive Manufacturing Market

Innovation Across Key Industrial Verticals

Israel additive manufacturing market sector is evolving as a backbone for modernization in:

Aerospace and Defense: Lightweight components, complex geometries, and high-performance materials enable operational efficiency and reduced lead times.

Healthcare: Customized prosthetics, implants, bioprinting, and surgical models offer patient-centric care and improved clinical outcomes.

Automotive and Industrial Manufacturing: Rapid prototyping, tooling, and small-batch production optimize supply chains and cut production timelines.

These sectors benefit from the convergence of additive technologies with AI, machine learning, and advanced robotics, all core competencies of Israel's high-tech sector.

Rising Demand for Customization and Sustainability

The shift toward sustainable manufacturing and personalized solutions is fueling AM adoption. Israeli startups and research institutions are developing biocompatible, recyclable, and multi-material printing solutions that meet stringent regulatory and industry-specific standards.

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Technological Landscape of the Israeli Additive Manufacturing Ecosystem

Polymer-Based Additive Manufacturing

Valued at USD 306.31 million in 2024, this segment dominates due to its cost-effectiveness, versatility, and compatibility with lightweight, complex part production. With an expected CAGR of 17.3%, applications in consumer goods, automotive interiors, and medical devices continue to surge.

Metal-Based Additive Manufacturing

Growing at a robust 20.1% CAGR, metal AM is the cornerstone of defense and aerospace advancements. In 2024, it accounted for USD 180.86 million, projected to exceed USD 775.48 million by 2032. Israel’s focus on titanium, aluminum alloys, and nickel-based superalloys supports structural applications with high thermal and mechanical stability.

Hybrid Additive Manufacturing

By blending subtractive and additive processes, hybrid AM enhances surface finish and dimensional accuracy, critical in precision tooling, aerospace, and dental prosthetics. This segment is rapidly gaining traction due to its versatility and integration into smart manufacturing systems.

Segmental Breakdown of the Israel Additive Manufacturing Market

By Component

Hardware: Represents the largest share, valued at USD 1,137.28 million in 2024, supporting high-throughput production and industrial-scale fabrication.

Software: Fueled by AI-powered design, generative modeling, and process simulation, this segment is experiencing 19.9% CAGR, revolutionizing digital twin applications and real-time process monitoring.

Services: The on-demand printing ecosystem is expanding, empowering SMEs to access advanced AM capabilities with minimal capital expenditure.

By Deployment Model

In-House Manufacturing: With a Israel additive manufacturing market valuation of USD 317.09 million in 2024, large enterprises prefer internal AM operations for confidentiality and operational control.

Service-Based Models: Growing at 19.4% CAGR, third-party service bureaus are crucial in democratizing access to advanced AM technologies for startups and research institutions.

By Functionality

Prototyping: Dominates with USD 340.60 million in 2024, essential for R&D, iterative design, and proof-of-concept validation.

Production: The rising shift to end-use part manufacturing is catalyzing growth in this segment, valued at USD 197.73 million in 2024.

Tooling: Customized, high-durability tooling supports faster transitions from design to production across various industrial sectors.

By Printer Size

Small/Compact Printers: Most accessible and dominant segment, valued at USD 253.09 million in 2024, ideal for labs, healthcare, and educational institutions.

Medium and Large Printers: Increasingly adopted in industrial manufacturing, these enable batch production and larger component fabrication.

End-Use Industries Driving Adoption

Aerospace & Defense

USD 159.32 million in 2024, this sector prioritizes weight reduction, material performance, and supply chain agility. With Israel’s defense sector being R&D intensive, 3D printing significantly enhances manufacturing autonomy and mission-readiness.

Healthcare & Medical

USD 131.40 million in 2024, growing due to demand for patient-specific devices, bioprinted tissues, and anatomical models. With innovations in regenerative medicine, Israel is at the forefront of personalized healthcare.

Industrial & Automotive

Israel’s industrial ecosystem leverages AM for lightweighting, thermal management, and low-volume production, especially in EV components and robotics enclosures.

Strategic Movements and Competitive Intelligence

Leading Israel Additive Manufacturing Market Participants

Stratasys: A global pioneer, deeply rooted in Israel, with continuous development in multi-material, high-resolution systems.

XJet: Revolutionizing ceramic and metal printing with NanoParticle Jetting™ technology.

Nano Dimension: Innovator in multi-layer electronics and PCB printing, driving miniaturization and functional integration.

Recent Developments

XJet (June 2024): Launched new ceramic printers with applications in automotive and aerospace, enhancing resolution and mechanical strength.

Nano Dimension (Sept 2024): Acquired startups to advance multi-material electronics printing, expanding their capabilities in embedded sensor systems.

Challenges and Strategic Opportunities

Major Israel Additive Manufacturing Market Challenges

Capital Intensity: High upfront costs limit adoption, especially among SMEs.

Talent Gap: Scarcity of AM-trained professionals hampers rapid scaling.

Scaling Complexity: Transitioning from prototype to full production requires new QA methodologies and workflow optimization.

Strategic Israel Additive Manufacturing Market Opportunities

Workforce Development: Partnerships with universities and technical institutes to offer AM-centric curricula.

Material Innovation Hubs: Support from government and private sectors to develop high-strength composites, bioresorbable materials, and nanostructured alloys.

Sustainability Mandates: Incentives for closed-loop manufacturing systems, energy-efficient printers, and recyclable materials.

Future Outlook: Israel’s Role in Global Additive Manufacturing Leadership

Israel is poised to lead the next frontier of digital manufacturing, where data-driven fabrication, machine learning-enhanced design, and autonomous production lines define industry 4.0. With unmatched cross-sector collaboration between startups, research centers, and government agencies, the nation’s AM sector is evolving from rapid prototyping to full-fledged production infrastructure.

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Conclusion

Israel additive manufacturing market is entering a golden era, driven by its technological prowess, strategic policy initiatives, and vibrant innovation culture. As the global demand for agile, sustainable, and customized manufacturing solutions intensifies, Israel is uniquely equipped to lead the charge. Enterprises, investors, and policy makers must align to fully harness this momentum and establish Israel as a global additive manufacturing powerhouse.

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[tenacioushandslovergoth-blog]

[3dprinterchat]

Mastering the Art of 3D Printing with Ender 3 Pro: Tackling Print Bed Adhesion Woes

So you got an Ender 3 pro? and you are having issues Embarking on a journey into the world of 3D printing can be an exciting yet challenging endeavour, especially when faced with print bed adhesion issues. If you find yourself grappling with stubborn prints sticking a bit too well, fear not. In this guide, we will delve into the nuances of optimizing your Ender 3 Pro, addressing common…

[materialsscienceandengineering]

From roots to rugged circuits: Tree-inspired printing tech for flexible electronics

A printing technology, inspired by the resilience of tree root systems, is set to redefine the future of conformal electronics. This innovation addresses long-standing challenges related to the mechanical stability and resolution of circuits on irregular surfaces, particularly in smart robotics and advanced sensing systems. By improving both the durability and precision of electronic circuits, this new method promises to withstand extreme conditions—such as high temperatures and mechanical stress—thereby vastly expanding the potential applications and reliability of conformal electronics. Conformal electronics, which are crucial for applications like smart skins and robotics, have long struggled with significant mechanical and thermal vulnerabilities. Traditional printing methods often produce circuits that are prone to tearing, cracking, and other forms of damage, limiting their performance and dependability.

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[eannpatterson]

Star sequence minimises distortion

It is some months since I have written about engineering so this post is focussed on some mechanical engineering.  The advent of pneumatic and electric torque wrenches has made it impossible for the ordinary motorist to change a wheel because it is very difficult to loosen wheel nuts by hand when they have been tightened by a powered wrench which most of us do not have available.  This has…

[harisharticles]

Will Additive Manufacturing Replace Traditional Manufacturing for Small Batches

Additive manufacturing, more popularly known as 3D printing, has evolved from a niche prototyping tool to a powerful industrial force. As industries chase efficiency, speed, and sustainability, the question arises: Will additive manufacturing replace traditional manufacturing? While some see this as an inevitable evolution, the reality is far more nuanced. Additive manufacturing complements traditional processes, and together they are shaping the future of production.

Understanding Additive Manufacturing Additive manufacturing builds objects layer by layer, using digital design files to create parts with intricate geometries that traditional methods struggle to achieve. This opens doors for rapid prototyping, custom parts, and on-demand production without the waste associated with subtractive techniques.

How Traditional Manufacturing Stays Relevant Traditional manufacturing methods such as casting, forging, and injection molding still dominate large-scale, high-volume production. These processes are cost-effective when mass producing uniform parts. The infrastructure, skilled labor, and supply chains for traditional methods are deeply rooted in global economies, making total replacement unlikely.

Where Additive Manufacturing Excels Additive shines in creating low-volume, complex, or customized components quickly. Aerospace, healthcare, and automotive industries use 3D printing for lightweight parts, patient-specific implants, and rapid tooling. Its design freedom reduces material waste, helping companies hit sustainability goals.

The Synergy of Additive and Traditional Methods Forward-thinking companies use both methods to balance speed, scale, and cost. Additive processes create prototypes or complex internal structures, while traditional manufacturing handles bulk production. This hybrid model drives innovation without overhauling entire production lines.

Challenges of Full Replacement Despite its advantages, additive manufacturing faces material limitations, slower production speeds for large batches, and high costs for certain metals and polymers. Regulatory approvals, especially in critical sectors like aerospace and medical, also slow full-scale adoption.

Industries Leading Hybrid Manufacturing Companies that integrate additive and traditional manufacturing are pushing boundaries in design and efficiency. This blended approach reduces time to market and allows for flexible, resilient supply chains—an advantage made clear during recent global disruptions.

For more info https://bi-journal.com/additive-manufacturing-collaboration-not-replacement/

Conclusion Will additive manufacturing replace traditional manufacturing completely? Unlikely. Instead, it complements conventional methods, unlocking new possibilities in design, production, and sustainability. Businesses that harness both technologies position themselves to lead the next era of smart manufacturing.

[wipro-3d]

Wipro 3D offers 3D printing solutions for the Automotive industry, enabling faster prototyping, reduced tooling costs, and lightweight designs

[architecturalthesis]

Some photos from the printing process

[pier-carlo-universe]

Il progetto europeo MIMOSA sviluppa giunzioni 3D tra metalli AM e carbon-fiber per velivoli più leggeri e riciclabili. Protagonisti TÜV Italia e Bytest, eccellenze nei test e nella certificazione. Scopri i risultati su Alessandria today.