3D Printing News & Discussions

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Team tackles support structure bottlenecks with dual-wavelength 3D printing

by Lawrence Livermore National Laboratory
https://phys.org/news/2025-06-team-tack ... ength.html
Lawrence Livermore National Laboratory (LLNL) researchers have developed a novel 3D printing technique that uses light to build complex structures, then cleanly dissolves the support material, expanding possibilities in multi-material additive manufacturing (AM).

In 3D printing, traditional supports often add time, waste and risk to the process, especially when printing intricate parts. But in a new study published in ACS Central Science, an LLNL team—in collaboration with University of California, Santa Barbara (UCSB) researchers—outlines a "one-pot" printing approach that uses two light wavelengths to simultaneously create permanent structures and temporary supports from a single resin formulation.
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The method addresses a longstanding challenge in AM: how to fabricate suspended or overhanging features without cumbersome scaffolding requiring manual removal, which is a key hurdle to the widespread adoption of digital light processing (DLP) 3D printing technologies.
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3D Printing Breakthrough: Scientists Create Functional Human Islets for Type 1 Diabetes Treatment
June 28, 2025

Introduction:
(Eurekalert) London, United Kingdom) A team of international scientists has made a major leap forward in diabetes research by successfully 3D printing functional human islets using a novel bioink. Presented today at the ESOT Congress 2025, the new technology could pave the way for more effective and less invasive treatment options for people living with type 1 diabetes (T1D).1

The breakthrough involved printing human islets – the insulin-producing clusters of cells in the pancreas – using a customised bioink made from alginate and decellularised human pancreatic tissue. This approach produced durable, high-density islet structures that remained alive and functional for up to three weeks, maintaining strong insulin responses to glucose and showing real potential for future clinical use.2

Traditional islet transplants are typically infused into the liver, a process that can result in significant loss of cells and limited long-term success. In contrast, the 3D-printed islets in this study were designed to be implanted just under the skin, a simple procedure requiring only local anaesthesia and a small incision. This minimally invasive approach could offer a safer and more comfortable option for patients.3

“Our goal was to recreate the natural environment of the pancreas so that transplanted cells would survive and function better,” explained lead author Dr. Quentin Perrier. “We used a special bioink that mimics the support structure of the pancreas, giving islets the oxygen and nutrients they need to thrive.”

To keep the fragile human islets safe during printing, the team created a gentler way to print by fine-tuning key settings – using low pressure (30 kPa) and a slow print speed (20 mm per minute). This careful approach reduced physical stress on the islets and helped keep their natural shape, solving a major problem that had held back earlier bioprinting attempts.

References:
1. Perrier Q., Jeong, W., Rengaraj, A., et al. Breakthrough in 3D printing: Functional human islets in an alginate-decm bioink. Presented at ESOT Congress 2025; 30 June 2025; London, UK.
2. Asthana, A., Amanda, E., Suárez, G., Lozano, T., N Byers, L., Ho-Heo, J., Jeong, W., Tamburrini, T., Rengaraj, A., Chaimov, D., Perrier, Q., Tomei, A., A Fraker, A., Jin Lee, S., Orlando, G. Comprehensive biocompatibility profiling of human pancreas-derived biomaterial. Front. Bioeng. Biotechnol., Sec. Tissue Engineering and Regenerative Medicine, Volume 13 - 2025, doi: 10.3389/fbioe.2025.151866 https://www.frontiersin.org/journals/b ... 665/full
3. Rajkumari, N., Shalayel, I., Tubbs, E., Perrier, Q., Chabert C., Lablanche, S., Benhamou, P., Arnol C., Gredy, L., Divoux, T., Stephan, O., Zebda, A., van der Sanden, B. Matrix design for optimal pancreatic β cells transplantation. Biomaterials Advances, Volume 164, November 2024, 213980
Read more here: https://www.eurekalert.org/news-releases/1088201
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Dual-light 3D printing technique enables seamless blending of flexible and rigid materials
https://techxplore.com/news/2025-06-dua ... mless.html
by University of Texas at Austin

The result of a new method for printing objects using novel resins provide flexibility, strength and complexity akin to what is found in nature. Credit: The University of Texas at Austin.

Inspired by how nature blends toughness and flexibility, such as the rigid structure of bone surrounded by pliable cartilage, all with elegant and precise geometric properties, researchers at The University of Texas at Austin have developed a fast, precise new 3D printing method that seamlessly merges soft and hard properties into a single object using different colors of light.

This advance could pave the way for next-generation prosthetics, flexible medical devices and stretchable electronics that move naturally with the body, much like a human joint or ligament. The process is described in a paper published today in Nature Materials.

"What really motivated me and my research group is looking at materials in nature," said Zak Page, an assistant professor of chemistry at UT Austin and corresponding author. "Nature does this in an organic way, combining hard and soft materials without failure at the interface. We wanted to replicate that."
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New 3D-printed titanium alloy is stronger and cheaper than ever before
By Abhimanyu Ghoshal
July 29, 2025
Apparently, folks in the material science world are totally over the fact that we're able to 3D print titanium alloys willy-nilly.

Because they have exceptional strength-to-weight ratios, corrosion resistance, and biocompatibility, titanium alloys are used to make aircraft frames, jet engine parts, hip and knee replacements, dental implants, ship hulls, and golf clubs.

Ryan Brooke, an additive manufacturing researcher at Australia's RMIT University, believes we can do way better. "3D printing allows faster, less wasteful and more tailorable production yet we’re still relying on legacy alloys like Ti-6Al-4V that doesn’t allow full capitalization of this potential," he says. "It’s like we’ve created an airplane and are still just driving it around the streets."
https://newatlas.com/materials/3d-print ... facturing/
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Czinger's 3D-printed hypercar breaks five track records in five days
By Utkarsh Sood
September 26, 2025
Driving 1,000 miles (1,609 km) of public road to set five official production car lap records in five consecutive days is no small feat – especially not for a car built with 3D-printed and machine-designed components. The Czinger 21C has just set a new benchmark for hypercar performance and endurance.

As a tribute to California’s car culture, the 21C broke lap records at five of the state’s most prestigious tracks: Thunderhill Raceway, Sonoma Raceway, Laguna Seca, Willow Springs Raceway, and The Thermal Club. The very car that achieved these times was displayed at this year’s Monterey Car Week.
https://newatlas.com/automotive/czinger-21c-gold-rush/
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3D printing becomes stronger and more economical with light and AI
https://techxplore.com/news/2025-09-3d- ... al-ai.html
by The Korea Advanced Institute of Science and Technology (KAIST)
Photocurable 3D printing, widely used for everything from dental treatments to complex prototype manufacturing, is fast and precise but has the limitation of being fragile and easily broken by impact. A KAIST research team has developed a new technology to overcome this weakness, paving the way for the more robust and economical production of everything from medical implants to precision machine parts.

Professor Miso Kim's research team in the Department of Mechanical Engineering has developed a digital light processing (DLP)-based 3D printing technology that fundamentally resolves the durability limitations of photocurable 3D printing. The paper is published in the journal Advanced Materials.
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The takeaway: With features such as multi-material printing, real-time monitoring, and adjustable build sizes – from small, intricate components to very large industrial parts – Oak Ridge National Laboratory's new system represents a major advance in additive manufacturing. The lab continues to test new combinations of extruders, materials, and software upgrades, aiming to push the limits of what can be produced with today's 3D printers.

Oak Ridge National Laboratory has developed a next-generation 3D printing system that aims to solve some of the persistent problems faced by industrial manufacturers working with large and complex designs. The highlight of this new technology is its multiplexed nozzle approach, which uses several smaller extruders working together instead of relying on one oversized, heavy extruder.
https://www.techspot.com/news/109690-oa ... match.html

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Room-temperature 3D-printing enables miniaturized infrared sensors
https://phys.org/news/2025-11-room-temp ... rized.html
by The Korea Advanced Institute of Science and Technology (KAIST)
Infrared sensors, which act as the "seeing" component in devices such as LiDAR for autonomous vehicles, 3D face recognition systems in smartphones, and wearable health care devices, are regarded as key components in next-generation electronics.

A research team led by Professor Ji Tae Kim of the Department of Mechanical Engineering at KAIST, in collaboration with Professor Soong Ju Oh of Korea University and Professor Tianshuo Zhao of the University of Hong Kong, has developed a 3D printing technique capable of fabricating ultra-small infrared sensors—smaller than 10 micrometers (µm)—in customized shapes and sizes at room temperature.

The paper, "Ligand-exchange-assisted printing of colloidal nanocrystals to enable all-printed sub-micron optoelectronics," is published in Nature Communications.
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Focused microwaves allow 3D printers to fuse circuits onto almost anything
By Omar Kardoudi
April 17, 2026
Engineers at Rice University have cracked one of printed electronics' most stubborn problems: how to cure freshly printed conductive ink without destroying the delicate surface underneath.

Their solution, published in Science Advances, uses a custom device that concentrates microwave energy into an area smaller than 200 micrometers (0.008 in) – heating only the newly deposited material to above 160 °C (320 °F) while everything around it stays cool.

The device is called a Meta-NFS, short for metamaterial-inspired near-field electromagnetic structure. Think of it as a magnifying glass for microwaves. It combines a split-ring resonator (a tiny loop that traps and amplifies electromagnetic energy) with a tapered tip that squeezes that energy into an almost impossibly small zone.
https://newatlas.com/electronics/meta-n ... -circuits/
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