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  • Why Additive Manufacturing Adoption Looks the Way It Does – Part I

    Additive manufacturing has been discussed for decades as a technology with the potential to reshape how products are designed and produced. Expectations have often focused on what the technology could enable in principle. Industrial adoption, however, has followed a more selective and uneven path.

    This article examines additive manufacturing from a structural perspective. Rather than emphasizing technical capability, it looks at the forces that have driven adoption, the challenges those forces introduced, and the industrial responses that followed. The goal is not to predict future outcomes or promote specific technologies, but to explain why additive manufacturing looks the way it does today.

    Understanding this context helps separate interest from deployment, capability from applicability, and potential from constraint.

    From rapid prototyping to selective industrial use

    Additive manufacturing technologies emerged in the late 1980s and early 1990s in response to a specific industrial need. The primary objective was to reduce the time and friction associated with design iteration. Early systems made it possible to translate digital models directly into physical objects without tooling, enabling faster form validation and earlier feedback in product development.

    The initial industrial response was concentrated in design and engineering environments. AM systems were adopted as development tools rather than as manufacturing equipment. Their value lay in compressing iteration cycles and improving communication between design, engineering, and downstream functions. In this phase, success was measured in time saved rather than in parts shipped.

    Several challenges limited broader use. Material properties were often inferior or insufficiently characterized for end use. Process stability and repeatability varied, dimensional accuracy was inconsistent, and surface quality frequently required secondary operations. Build rates were low, and cost per part was high compared with established manufacturing methods. These constraints were well understood and shaped how AM was positioned within organizations.

    From the mid 2000s onward, improvements in machine capability, process control, and material quality began to change the decision context. In controlled settings, certain AM processes demonstrated mechanical properties comparable to those of conventionally manufactured parts. This did not remove earlier constraints, but it altered the balance between limitations and the value AM could deliver.

    VulcanForms has created digital production systems based on its industrial 3D printing technology. Image courtesy of Joseph Seif.

    The industrial response remained selective. Rather than a broad shift toward AM based production, adoption occurred in applications where functional performance, geometric freedom, or customization outweighed cost and throughput considerations. Aerospace components, medical implants, dental products, and specialized tooling inserts became early production use cases. In these contexts, AM was integrated as a manufacturing route for specific part families, not as a replacement for existing production systems.

    This transition was incremental. Additive manufacturing did not move cleanly from prototyping to production. It expanded its role by accumulating narrowly defined industrial use cases over time. Even as production applications increased, AM continued to coexist with conventional manufacturing processes, each addressing different constraints and value criteria.

    The resulting pattern established many of the structural characteristics that continue to shape additive manufacturing today. Early adoption was driven by iteration speed. Later, industrial use emerged where performance justified added complexity. Much of the public discussion around additive manufacturing still focuses on technical capability. The sections that follow examine instead what has driven adoption in practice and what has consistently constrained it.

    This first installment has focused on how additive manufacturing moved from a rapid prototyping tool to a selective production method. In Part 2, the analysis turns to the forces that shaped industrial integration more directly: performance requirements, regulatory environments, and the influence of market cycles and capital.

    Ulf Lindhe. Image courtesy of The Org.

    About the Author:

    Ulf Lindhe is a veteran executive in the additive manufacturing industry with decades of experience spanning technology development, industrial strategy, and global market expansion. He has held senior leadership roles within the metal additive manufacturing sector, contributing to the commercialization and international growth of advanced AM systems. Over the course of his career, Lindhe has worked closely with aerospace, medical, and high-performance engineering companies, helping bridge the gap between technological capability and practical industrial deployment.

  • Fancy a Fidget? Product Designer Sells Her 3D Printed Fidget Clickers at Pop-Up Shops

    The hottest toy in 2017 was undoubtedly the fidget spinner, which initially began as a tool to help students with ADHD and special needs relieve anxiety and refocus their energy. But they’ve grown in popularity since then, and the market is massive, with millions of self-soothing fidgets owned by children and adults alike. Singaporean product designer Jennifer Ang is one of the many people using 3D printing to create fidget toys.

    “As a product designer, I found it so amazing that 3D printers can turn ideas into reality almost instantly,” said Ang, solopreneur of Heyo.makers, a gift shop for customized 3D printing. “You can do testing within hours, without sending it to a supplier for mock-ups and waiting a week.”

    Ang first used 3D printing when she was an Industrial Design student at Nanyang Polytechnic, and continued to do so at her first job as an industrial designer for a design consultancy firm. At the same time, she was also teaching classes on product design and 3D printing, and eventually left her full-time role for a part-time one to pursue a bachelor’s degree in design from the Singapore Institute of Management (SIM) and Royal Melbourne Institute of Technology (RMIT).

    At her own business, Ang offered product design services and taught courses, and in 2017 purchased her first 3D printer, from Taobao, which was the opposite of a plug and play system. At first, it was just a personal hobby, but like so many others, Ang had to pivot during the pandemic, and started selling customized 3D printed keychains, coasters, phone stands, and bag tags on Shopee. She eventually invested in some better printers, like the Bambu Lab A1, which enabled her to eventually sell her products on Carousell, Lazada, and TikTok.

    Ang wanted to expand into pop-ups, but realized that her custom 3D printed offerings weren’t conducive to that kind of business; not everyone has the time to wait an hour or more for a product to be fabricated. That’s when she had the idea to sell fidget toys, specifically fidget clickers, at a pop-up.

    “Many of us fidget as a way of emotional self-regulation. We may click on a pen, twirl our hair, play with jewellery or tap on the table to soothe anxiety,” Ang explained.

    “That is how fidget clickers work. And in some ways, they can be a habit replacement – to fidget in a nicer way.”

    These fidget clickers are exclusively available at heyo.makers’ pop-up stores. (Photo: heyo.makers)

    Ang, like me, is a pen clicker, noting that she finds “the click and bump therapeutic” and that it helps her focus. She realized she could get the same feeling from her computer’s mechanical keyboard, and decided the products at her pop-up shop would be fidget clicker keychains, with customizable keycaps she designs and prints at home.

    The Heyo.makers keycaps feature designs like cursive fonts, smiley faces, cute characters, and Singaporean snacks. While they can be used on a custom keyboard, they’re actually meant to go on a keypad-like keychain base that you can attach to your bag and click to your heart’s desire.

    Ang ran her first pop-up in the fall of 2025, and 3D printed about 200 keycaps to sell at PLQ Mall in Paya Lebar. While she was initially worried that they might not sell, customers ended up buying around 30 fidget clickers with 120 keycaps on her very first day.

    She said, “I thought that fidget clickers would appeal more to kids, but it turns out that adults like them as well, especially women.”

    The design and printing of fidget clickers are very precise. “0.02mm off and the keycaps may not fit well in the base,” says Ang. (Photo: heyo.makers)

    The clicker base comes in different sizes, holding anywhere from one to nine keycaps. Customers can choose from more than 400 different keycap designs, and three types of clickers: one with a loud click and bump, another with just a bump, and one that’s very quiet. Prices for the fidget clickers and keycaps range from S$8 to S$48.

    Ang’s first pop-up did so well, she’s since offered four additional ones at other locations, and has sold over 1,000 fidget clickers since October of 2025. She only offers the clickers at her pop-ups, but still sells her other 3D printed products on e-commerce platforms.

    “What I love most is the chance to bring my own ideas to life while connecting directly with customers,” Ang said. “Seeing people enjoy what I create is incredibly rewarding.”

    She may even expand to creating custom keyboards or other kinds of fidget toys, noting that “once you know how to do 3D design, the possibilities are endless.” This is yet another example of how 3D printing can be a really great tool for small businesses!

  • 3D Printing News Briefs, February 28, 2026: Sales Partner, Holographic 3D Printing, & More

    We’re kicking off today’s 3D Printing News Briefs with some business news, as Meltio has announced a sales partner in the U.S. and Immensa has joined Shell’s Energy Transition Campus. Moving on, researchers from Tsinghua University developed a system that can print tiny objects almost instantaneously. Finally, Aectual designed 3D printed ceilings and storefront elements for lululemon.

    Meltio Sales Partner AEC Helping Improve Growth in U.S. Metal AM Market

    Spanish multinational Meltio announced that Automation Engineering Company (AEC) is its latest official sales and integration partner in the United States. Based in South Carolina, AEC is a trusted machine builder and automation integrator, and will help Meltio expand growth of its industrial wire laser metal deposition technology in the U.S. metal AM market. This partnership is an important strategic step in Meltio’s continuing expansion into the U.S. Its W-LMD solutions are already being used across the country in industrial environments for demanding sectors, such as energy, heavy industry, and oil & gas. As a sales partner and systems integrator for Meltio, AEC will work to develop a strong ecosystem for Meltio’s solutions in the U.S. by supporting and distributing its technology, and building strong relationships and business opportunities with industrial customers, machine tool builders, academic institutions, technology centers, and others who would appreciate the welding wire-based technology.

    “By combining AEC’s deep experience in advanced robotic welding and turnkey automation systems with Meltio’s blue-laser, wire-fed metal 3D printing technology, we can deliver practical, production-ready additive solutions,” said Bobby Larmer, CEO of AEC. “This welding-wire-based process gives manufacturers a safer, cleaner, and more cost-effective path to high-deposition, near-net-shape production, repair, and hybrid manufacturing. It’s a strong fit with our mission to engineer real-world solutions that improve performance, flexibility, and ROI for our customers.”

    On-Demand AM Firm Immensa Joins Shell’s Energy Transition Campus Amsterdam

    Immensa, the leading on-demand additive manufacturing and digital inventory solutions provider in the Middle East and North Africa (MENA) region, has joined Shell’s Energy Transition Campus Amsterdam (ETCA). This is Shell’s open innovation campus for industry, research, and technology to work together to speed up the energy transition towards cleaner solutions, offering a purpose-built environment for industrial advanced manufacturing. Based in Saudi Arabia and Dubai, this move will enable Immensa to grow its footprint in Europe. The company will establish a European Center of Excellence for Advanced Manufacturing at ETCA, and operate a Factory-as-a-Service model to support customers in reducing lead times and physical inventory, and improving supply chain resilience, through digital, localized production. Immensa will collaborate with Shell’s Additive Manufacturing team to operate ETCA’s 3D Printing Centre of Excellence and deliver its Digital Supply Chain offering. Initially, the partners will focus on long-lead spare parts for compressors, pumps, and valves.

    “ETCA provides the right ecosystem for our next phase of European growth. The campus enables us to deliver advanced manufacturing solutions closer to our customers while maintaining the high standards required in regulated industries,” Immensa’s Chief Operating Officer Julian Callanan said.

    Tsginhua University Researchers Report Holographic 3D Printing Breakthrough

    In what could be a breakthrough for drug testing, regenerative medicine, micro-robotics, and flexible electronics, a team of researchers at Tsinghua University in China reportedly developed a system that can print intricate objects at millimeter scale in less than one second. Essentially, they’re converting digital holograms into physical 3D objects. Typical extrusion-based 3D printers use precision nozzles and mechanical gantries to stack layers, which can take hours. The team’s technique, called Digital Incoherent Synthesis of Holographic light fields (DISH), solidifies an entire object at once by projecting a 3D holographic light field directly into a resin volume. Using controlled light, DISH acts more like a volumetric projector, using a high-speed, rotating periscope to project light into the resin from many angles. Then, the holographic fields overlap to form precise, complex microscale structures: no layering or waiting, and no having to choose between fast output or fine details. The team tested their technique, and say they were able to create fully formed 3D objects in only 0.6 seconds, at the same time preserving structural details down to 12 micrometers.

    “The iterative optimization of the holograms for different angles in DISH maintains 19-μm printing resolution across the 1-cm range that is far beyond the depth of field of the objective and enables high-resolution in situ 3D printing of millimetre-scale objects within only 0.6 s. Acrylate materials in a range of viscosities are used to demonstrate the general compatibility of DISH. Integrating DISH with a fluid channel, we achieved mass production of complex and diverse 3D structures within low-viscosity materials, demonstrating its potential for broad applications in diverse fields,” the researchers wrote in their paper.

    Aectual Rolls Out 3D Printed Ceilings and Storefronts for Lululemon

    Earlier this month, we reported that the new lululemon flagship store in SoHo featured custom 3D printed benches and a display shroud. The activewear company seems to be continuing its push into the 3D printing space. Its global design team is partnering with Dutch additive design firm Aectual to develop and roll out signature 3D printed ceilings and storefront systems for some of its key stores around the world. Aectual’s custom large-scale 3D printing technology is able to fabricate double-curved architectural panels, which seamlessly connect to form continuous surfaces. The robotic system turns lululemon’s branding and design lines into a “spatial form,” and all the ceilings and storefront elements are printed using Aectual’s recycled consumer waste material blend. Whenever the ceilings and storefronts reach their end of life, they can then be returned, via Aectual’s Circular Service, and reprinted into new products. The first lululemon ceiling and storefront elements premiered in Milan, and added to the company’s SoHo location; further locations are already underway in Tokyo and Birmingham, with more to come.

    “Our new store expression reflects lululemon’s commitment to creating a welcoming, dynamic retail experience, designed to celebrate our product and community. Every detail has been curated to evoke emotion and connection, with elevated materials to reflect the quality and craftsmanship of our products,” said Darin Rabb, Senior Vice President, Global Brand Creative & Experience, lululemon.

  • AM I Navigator and Leading Minds Launch AM Alliance at AMS 2026

    At Additive Manufacturing Strategies (AMS) 2026, which just wrapped up in New York City yesterday, AM I Navigator and the Leading Minds consortium announced a new alliance aimed at accelerating the industrial adoption of additive manufacturing. The news was formally unveiled on February 26 during the event, marking one of the key strategic announcements coming out of this year’s show.

    The two additive manufacturing groups have “joined forces,” as Materialise CEO Brigitte de Vet-Veithen put it during the live announcement, under a newly formed umbrella organization called the Additive Manufacturing Alliance. The goal is to make additive manufacturing (AM) easier to understand, easier to implement, and more widely used in industrial production. de Vet-Veithen was joined onstage by Karsten Heuser, VP Additive Manufacturing for Siemens, for the exciting announcement. The companies are partners in both initiatives.

    Materialise CEO Brigitte de Vet-Veithen and Karsten Heuser, VP Additive Manufacturing, Siemens, onstage at AMS 2026

    A New Alliance Focused on Industrial Adoption

    The new Additive Manufacturing Alliance brings together two established efforts that already work toward similar goals but from different angles.

    Rather than merging into one entity, Leading Minds and AM I Navigator will continue operating independently where appropriate. However, they will now collaborate on selected activities, particularly around knowledge sharing, communication, and helping manufacturers move from early experimentation to scaled production.

    “Our shared goal is to make additive manufacturing more accessible, less complex, and more integrated into everyday industrial production. Together, we can help more companies across a wider variety of industries benefit from the flexibility, efficiency, and innovation that AM enables,” said de Vet-Veithen, CEO of Materialise, speaking on behalf of the newly formed Alliance.

    What this means is the Alliance aims to connect awareness with execution. Leading Minds focuses on building understanding and reducing confusion around AM, while AM I Navigator provides structured tools and guidance to help companies industrialize and scale their additive manufacturing operations. Together, they seek to help companies move from inspiration to implementation.

    How AM I Navigator Helps Companies Scale AM

    The AM I Navigator is a structured tool that helps companies assess and improve their additive manufacturing maturity. It was first launched at Formnext 2023 by Siemens, DyeMansion, HP, BASF Forward AM, and EOS. Since then, it has grown into a broader ecosystem that includes partners such as Materialise, AMTPro, AZO, and knowledge partners, including Capgemini and BCG.

    At its core, the AM I Navigator provides a structured way for companies to evaluate and improve their use of additive manufacturing. It includes a five-stage model that helps organizations understand how advanced they are, guidance across key areas such as strategy, design, production, quality, and organization, and practical insights drawn from real industrial use cases. Companies can also access online self-assessment tools to measure their progress and identify next steps.

    Companies use the framework to benchmark their current capabilities and develop roadmaps toward higher levels of automation, quality, and economic performance. The goal is to help organizations move beyond pilot projects and into repeatable, scalable production.

    According to Heuser, “Via the newly launched AM I Navigator website, companies worldwide can independently and free of charge assess their additive manufacturing maturity and explore transformational insights derived from proven industrial applications. The assessment tools are voluntary resources designed to help companies of all sizes, from startups to global manufacturers, benchmark their capabilities and identify improvement opportunities.”

    The maturity model and related tools are accessible at: https://am-i-navigator.com/.

    Another announcement tied to the Alliance is the addition of Wohlers Associates, powered by ASTM International, as a Knowledge Partner within the AM I Navigator network. Wohlers Associates brings experience in standards, certification, and helping companies prepare additive manufacturing for demanding industries such as aerospace, defense, and medical.

    Mohsen Seifi, Vice President of Global Advanced Manufacturing Programs at ASTM International, stated that, “By joining the AM I Navigator, we aim to contribute our experience in translating additive manufacturing standards into robust industrial practice. Together with the partner network, we want to help manufacturers accelerate the transition from experimentation to qualified, scalable production.”

    Leading Minds: Simplifying Industrial AM

    The second initiative behind the new Alliance, Leading Minds, was first announced at Formnext 2024 as a consortium of eight founding companies: Ansys, EOS, HP, Materialise, Nikon SLM Solutions, Renishaw, Stratasys, and ATLIX (formerly Trumpf Additive Manufacturing).

    The consortium has two primary objectives: to increase awareness of additive manufacturing across industries and reduce the barriers companies face when adopting and scaling AM.

    One of its first major initiatives addresses a long-standing issue in the industry: inconsistent terminology. Different companies often describe similar processes using different language, which can create confusion and slow adoption.

    Leading Minds is developing an open, common language framework for additive manufacturing. The framework is designed to standardize communication across the production process, making discussions with customers clearer and more actionable. The group says the framework has already been expanded to cover the full AM production chain and is actively being used with customers.

    In addition to terminology work, Leading Minds continues to participate in major industrial events in North America and Europe, targeting sectors where AM adoption remains early but promising.

    A New Member Joins Leading Minds

    The consortium also announced that the Manufacturing Technology Deployment Group (MTDG) has joined as its newest member. MTDG, along with its subsidiary, the National Center for Defense Manufacturing & Machining (NCDMM) and its America Makes program, focuses on helping manufacturers deploy advanced manufacturing technologies and supporting educational institutions in embracing these technologies.

    Dean L. Bartles, President and CEO of MTDG, will represent the organization within Leading Minds. “MTDG is honored to join the Leading Minds consortium at such a pivotal moment for our industry,” noted Bartles. “Through the combined strengths of MTDG, NCDMM, and America Makes, we remain deeply committed to advancing the industrialization of additive manufacturing and expanding its impact across the manufacturing ecosystem.”

    L-R: Karsten Heuser, VP Additive Manufacturing, Siemens; Mohsen Seifi, VP Global Advanced Manufacturing Programs, ASTM International, Dean Bartles, CEO and President of MTDG; and Brigitte de Vet-Veithen, Materialise CEO

    The announcement at AMS 2026 highlights a broader effort within the additive manufacturing industry to move beyond small pilot projects and toward larger-scale production. Through the new Alliance, Leading Minds and AM I Navigator aim to support that shift with clearer communication, shared standards, and practical tools.

    Images courtesy of Sarah Saunders for 3DPrint.com

  • AMUG 2026 to Feature LEGO, Aerospace Collaboration Keynotes

    AMUG 2026 puts the spotlight on the people and partnerships driving additive manufacturing forward. According to AMUG’s pre-conference overview, this year’s agenda reflects cross-industry collaboration, hands-on learning, and tangible business impact.

    One of the keynotes will feature Ronen Hadar, who leads additive manufacturing at The LEGO Group. His talk will offer insight into how a major global brand uses additive technologies. Another anticipated session on Tuesday will feature Steve Fournier of General Atomics and Scott Sawyer, Director of Aerospace and Defense programs at Divergent, who will explain how a connection they made at AMUG turned into a partnership between aerospace and automotive in their joint keynote titled “From Hypercars to Defense Drones: How Two Major Industry Innovators Started Their Partnership Journey at AMUG.” The keynote highlights one of AMUG’s biggest strengths, bringing together users from different industries who might not otherwise cross paths. Fournier and Sawyer plan to explore a larger question that resonates across the industry: how effective is knowledge transfer at conferences, and what does it actually translate to in terms of growth, differentiated capabilities, and revenue?

    AMUG recently confirmed this session as its second official keynote for 2026, pointing to how central this collaboration story is to the conference theme. Both General Atomics Aeronautical Systems and Divergent have independently been recognized as power users of additive manufacturing, one in defense aerospace and the other in automotive hypercars. The partnership itself traces back to a 2022 AMUG connection following a keynote by Divergent founder Kevin Czinger. Now, Fournier and Sawyer will outline what changed once those parallel expertise tracks intersected, offering a concrete example of how industry conversations can evolve into measurable industrial outcomes, including new capabilities, hardware development, and business transformation.

    Another key moment will be during the Innovators Showcase on Wednesday, March 18, when Max Lobovsky, co-founder and CEO of Formlabs, receives the 2026 Innovators Award. Lobovsky has been a key figure in expanding access to professional-grade desktop stereolithography systems, helping bring industrial-quality 3D printing into a wider range of businesses, labs, and classrooms. On stage, he’ll discuss the company’s growth and what’s next for affordable, professional 3D printing.

    2025 DINO Award recipients (from left): Patrick Gannon, Brennon White, Dallas Martin, Amy Alexander, Ryan Kircher, and Dan Braley. Image courtesy of AMUG.

    Beyond the keynotes and awards, the technical sessions show where the industry is going. One topic is multi-sensor in situ monitoring for part qualification, which many see as key to speeding up certification in aerospace and defense. Another session looks at how AI is being used for reverse engineering and qualification, helping companies validate designs faster and move through approval processes more efficiently. The program will also cover automotive production, including how manufacturers are scaling up 3D printed heat exchangers for hypercars.

    Healthcare will also be part of the program, including a discussion on whether bioprinting could play a bigger role in medical manufacturing. At the same time, sessions on America Makes projects will share practical lessons from working on some of the defense industry’s toughest additive challenges.

    AMUG also continues to focus on hands-on learning. Workshops that combine silicone molds, casting, and 3D printing show how additive manufacturing can work alongside traditional manufacturing. For many attendees, these sessions offer practical ideas they can take back home and apply right away.

    Meanwhile, the Start-up Launchpad program highlights early-stage companies working on new additive technologies and applications. It gives them space to present their ideas and connect directly with experienced users and industry leaders.

    Overall, the AMUG 2026 program reflects an industry that is growing and becoming more practical. Topics like certification, AI, production scale, and cross-industry collaboration are all on the schedule. But at its core, the event is still about people coming together to share their experiences.

    As AMUG 2026 approaches, the program reflects how the conference has evolved over the years. What began as a gathering of early adopters has grown into a working forum for experienced users focused on qualification, scale, and real production results. This year’s agenda suggests that additive manufacturing is entering a more disciplined phase, one defined by collaboration, measurable outcomes, and practical implementation.

    AMUG 2026 runs March 15–19, and 3DPrint.com’s Managing Editor Sarah Saunders will be onsite to follow the conversations and developments firsthand.

  • Melotte Partners with amsight and Additive Center to Reduce CT Scanning for 3D Printed Semicap Parts

    The first report for Additive Manufacturing Research (AMR) that I wrote solo was about the AM market opportunity in semiconductor capital equipment (semicap) components. Published in early 2024, the report was one I personally pushed for, because of how much I believe that AM aligns with the needs of semicap manufacturers.

    Two years later, the report is arguably more relevant than it was at the time of its initial publication: the uncertainty of the AI boom trajectory dictates that semicap OEMs need to be as flexible as possible in their production strategies, an objective that AM can help them meet. A recently-announced partnership between German software provider amsight, Dutch consultancy Additive Center, and service bureau Melotte (also based in the Netherlands) demonstrates how the semicap market may soon have an even easier path to scaling its use of metal AM.

    A startup based in Hamburg specializing in AM software solutions that support end-to-end quality control (QC), amsight worked with Additive Center to implement “a comprehensive data capturing system” at Melotte’s Netherlands facility, which enables the service bureau to trace every step of the print process, from materials through final inspection. That very last step is in fact the key differentiator, according to the companies involved in the effort: by tracing the entire process so meticulously, they claim they’ve achieved a milestone in reducing the need for CT scanning.

    It’s especially noteworthy that, as the companies point out in the press release, this isn’t a theoretical capability, but rather one that’s currently operational in Melotte’s workflow, and is already being used to streamline the print process for semicap components. According to the partners, they plan to follow up on the first phase of implementation by leveraging the data gained to create a set of ‘Critical-to-Quality’ (CTQ) parameters.

    In a press release about the partnership between amsight, Additive Center, and Melotte to establish an AM data-capturing protocol at Melotte’s production facility in the Netherlands, Harry Kleijnen of Additive Center said, “The industry often mistakes ‘machine monitoring’ for ‘process control’. What we have achieved with Melotte and amsight is the integration of the total process. We aren’t just looking at the laser; we are looking at the entire lifecycle of the part. This is the first step towards increasing process understanding and thus reducing the use of CT scanning.”

    One of the companies at the center of the report I wrote in 2024 was ASML, a Dutch company that is perhaps the singular most important link in the global semiconductor supply chain. ASML has been using metal AM for end-use parts for over a decade, making it one of the most experienced metal AM users in the world.

    It’s worth mentioning that ASML works with Additive Center on at least one AM educational initiative. Plus, given the geographical proximity of Additive Center and Melotte to ASML’s headquarters, ASML will likely be one of the beneficiaries of the enhanced capabilities that Melotte has acquired thanks to amsight. In any case, the partnership reinforces the idea that semicap OEMs have a sustained long-term interest in accelerating the scalability of metal AM.

    With all that in mind, while the amsight/Additive Center/Melotte project is already paying off for Melotte’s existing operations, I think that the true potential of the work lies in how it could change the timeline for the semicap industry’s AM adoption journey. Any step in the printing process that can be sped up and made less expensive brings AM that much closer to competing with other manufacturing processes.

    Thus, the output gains yielded by a reduction of the use of CT scanning could be precisely the thing that convinces a company like ASML to plan for more metal AM components across its supply chain. And, if this early stage of the data-capturing process proves successful, amsight and its partners will have created a model optimizing other steps in the metal AM workflow.

    Image courtesy of amsight

  • Alloyed Develops New 1000°C Alloy for 3D Printed Flight-Ready Jet Engine Parts

    Nickel-based superalloys and music (Bing Crosby and Fred Astaire, for starters) were best in the 1930s. Inconel and Hastelloy were invented in that decade, along with Scotch tape, the car radio, and instant coffee. When FDR was president and the Second World War was set to occur, the cutting-edge high temperature materials were more or less the same as the ones popular now. Now that’s kind of stupid, because it was before the DC 2 was commercialized, and now in hypersonics and sixth generation aircraft, we are stuck with the same materials. Time to ditch the 100-year-old materials, or perhaps make some money with a quick visit to “Antiques Roadshow.” I hope that your antique nickel superalloys surprise your neighbors.

    UK-based firm Alloyed was trying to find an alloy that could be used at over 1000°C. The company has now created ABD-1000AM specifically for jet engines. Alloyed worked with propulsion and MRO firm ITP Aero and Cranfield University on the alloy, while being funded by the ATI Programme—part of the Aerospace Technology Institute—the Department for Business and Trade, and Innovate UK. In total, that program will spend £14 million trying to make it easier to qualify flight-ready 3D printed parts.

    Alloyed Chief Metallurgist Dr David Crudden said,

    “Alloyed have been fortunate to have the opportunity to partner with the ATI in several key technology areas ranging from design of new materials to the development of digital software platforms to support adoption of additive manufacturing in the aerospace industry. This project, focused on advancing the manufacturing readiness level of ABD-1000AM, is a great example of where ATI Programme funding helps UK companies to bridge the gap between early research and industry development programs.

    “ABD-1000AM is the world’s highest temperature nickel-based superalloy designed for additive manufacture. We have identified huge demand for this material and believe it will be a game changing technology for gas turbines across aerospace propulsion and industrial power generation.”

    Chris McDonald, Parliamentary Under-Secretary of State Minister for Industry, stated,

    “This is a strong example of how government and business can work together to keep the UK at the forefront of innovation in our world-class aerospace sector, and I look forward to seeing how Alloyed’s project can contribute to the jet engines of the future. We’re bolstering our support for the aerospace industry through our modern Industrial Strategy – giving business the confidence it needs to invest in UK advanced manufacturing and delivering on growth as part of our Plan for Change.”

    Now we can all agree that a plan for change sounds fantastic.

    ABD-1000AM microstructure

    Rob Mitchell, ITP Aero UK´s Director of Engineering said,

    “ITP Aero is committed to a wide range of research and development programmes across the regions in which it operates. AMRAM is another good example of how partnering across academia, SMEs and industrial partners can directly shape the future of the aerospace industry.”

    This is super nice news generally. A nice UK group hug for Rolls Royce for sure. At the same time, this kind of development will help the UK, both commercially and in defense, stay on the cutting edge. Custom and new alloys are sorely needed to advance turbo machinery. At the same time, the UK is kind of in a state of flux. A longtime US alloy periodically aloof to its neighbors, it wants to remain strong and relevant worldwide. Over the past decades, the UK´s cultural and linguistic closeness with the US has allowed it to maintain its relevance while cooperating closely with the US. A position as part of the European Union gave it the benefits of that block as well. This Euro-Atlantic straddle is now impossible after it left the EU due to a new US disengagement. The UK may seem like an island, but it is in reality adrift.

    With limited means, the country is trying to once again find its place in the world. Its own alloys, and its own alloy-making ability, are a tempting way to turn to material science and development to seek an edge. With Alloyed, Metalysis, mining giants such as Rio Tinto, and steel companies like Tata, as well as Renishaw, the UK actually has more than a chance to make this a reality. Other similarly-sized countries would be hard pressed to find the capabilities that the UK has.  As we detailed in the RCCA article, an age is upon us where computational advancements, new powder fabrication methods, 3D printing as a way to create alloys, and 3D printing as a manufacturing technology combine to make a new world of custom alloys possible. The US and China are engaged in a dual power competition around new alloys. But, what of other countries? Should they trust the US and its alloys systems? Or should they too strive to develop sovereign cutting-edge alloy capabilities? In a fractious world, this formerly fantastical notion could be a very sound idea indeed.

  • 6K Additive Lands Long-Term Nickel-Alloy Powders Supply Agreement with Siemens Energy

    We’ve still got a month left in Q1, but I’ve already come back to the theme of the role of additive manufacturing (AM) in the ‘sustainability-as-security’ thesis — a topic that I’ve been focused on for years — more than once in 2026. This is very welcome news for anyone who believes in AM’s growth potential.

    6K Additive exemplifies the sustainability-as-security case about as well as any other company, and the metals supplier just reinforced its position by announcing a long-term deal with Siemens Energy to source nickel-based alloy powders from the cleantech giant. 6K Additive will process nickel-based revert powder — scrap from in-house production — from Siemens Energy into new feedstock, supporting 6K Additive’s goal to build a circular economy for metal AM.

    6K Additive notes that it has already processed nearly 20 tons of such powder from Siemens Energy, which the former subsequently supplied to the AM market. Siemens Energy has historically been one of the world’s largest metal AM users, giving 6K an ideal pipeline for high-quality scrap.

    Siemens Energy, meanwhile, has been massively ramping up its investments into the US market, focusing on supporting the AI boom with grid infrastructure and gas turbine equipment, among other applications. According to the company, its latest investment of $1 billion will create over 1,500 skilled jobs in the US.

    In a press release about 6K Additive’s long-term deal with Siemens Energy to source nickel superalloy scrap, the CEO of 6K Additive, Frank Roberts, said, “Siemens Energy is a strong example of an industrial partner committed to advancing circularity. Their consistent and high-quality feedstock enables us to produce premium nickel alloy powders using our UniMelt process, delivering meaningful reductions in energy use and carbon emissions while supporting the growing demand for sustainable AM materials.”

    The Head of Finance for AM at Siemens Energy, Steve Sarcander, said, “At Siemens Energy, sustainability and responsible resource use are integral to how we approach advanced manufacturing. By supplying our revert material into 6K Additive’s production process, we are supporting circular material flows while helping to reduce waste and emissions associated with metal powder production. Partnerships like this play an important role in strengthening the overall [AM] value chain.”

    Given the sustainability-as-security context, and the fact that this particular story involves a deal between a US company and a European one, I think it makes the most sense to view the agreement through the lens of US-EU trade relations. On the surface, while the relationship between the US and its European allies has rarely looked rockier, there are nonetheless reasons to believe that the trade dynamics could emerge on the other side of the turmoil in stronger shape than ever.

    For one thing, even after President Trump imposed new, harsher tariffs on trading partners, including the EU, following the Supreme Court’s rejection of the tariffs that Trump has imposed since retaking office last year, the EU’s trade chief stated that he’s confident that the US will “ease” tariffs on metal products coming from the EU in the weeks ahead. Since metals in general, and critical minerals in particular, have become so central to the ongoing trade negotiations between the US and the EU, that statement suggests that a major breakthrough could be on the horizon for the monumental deal the US and the EU struck in the summer of 2025.

    For another thing, speaking of that same trade deal — it hinges on energy flows from the US to Europe, and European nations have few options aside from the US when it comes to replacing baseload power supplies from Russia. This means that a deal between the EU and the US is in everyone’s interests regardless of what happens with tariffs, and the EU is simply now in a better bargaining position than it was prior to the Supreme Court ruling.

    Assuming some version of the deal goes through, the outcome could result in many more business agreements that look like the one between 6K Additive and Siemens Energy. The West appears to be trending towards a scenario where North America and Europe become more interdependent on critical infrastructure supply chains, and one side provides the raw materials while the other provides the finished goods.

    Interestingly, the nature of this dynamic that’s currently in discussion suggests that the relationship will most often work the other way around from the 6K/Siemens Energy arrangement, with the US supplying critical minerals and the EU providing the parts. But if true circular economy for AM can actually be cultivated, it will open up any number of possibilities for rearranging the elements within the overall trade framework.

    Image courtesy of 6K

  • BigRep Expands into the Auto Aftermarket Through SEMA’s 6,000-Member Network

    Several months ago, 3DPrint.com Executive Editor Joris Peels made a good case for aftermarket car parts as a potential high-growth opportunity for additive manufacturing (AM), specifically in the context of automotive seating. 3D printing for aftermarket car parts isn’t a new idea, but Joris’s spin on the concept emphasized how aesthetic and comfort, rather than repairs, look poised to add a whole new dimension to aftermarket demand that would benefit both the AM industry and automakers.

    BigRep America, the original equipment manufacturer (OEM) of large-format, polymer extrusion 3D printers, just secured a deal that validates Joris’s theory: BigRep is partnering with SEMA Garage, the product development and technology center for the Specialty Equipment Market Association (SEMA), to give SEMA members access to BigRep’s production hardware. SEMA Garage will house a BigRep STUDIO industrial-grade machine at its facility in Diamond Bar, CA, located in the Los Angeles area, providing an entry for BigRep into SEMA’s network, comprised of thousands of member companies.

    While SEMA is involved in all aspects of the auto aftermarket landscape, restyling has historically been one of the organization’s main focus areas, and the passion for individualized car aesthetics was a main catalyst behind SEMA’s founding over 50 years ago.

    BigRep, for its part, has extensive experience in the auto sector, including relationships with major OEMs like Ford, as well as with NASCAR teams like Legacy Motor Club. The German company has continued to push into the North American market since going public on the Frankfurt Stock Exchange in 2024.

    In a press release about BigRep’s partnership with SEMA Garage, the president of BigRep America, Jeff Olson, said, “We couldn’t be more excited about this partnership with SEMA Garage. It’s a meaningful step forward in how we bring large-format [AM] to the automotive industry in North America. The automotive sector has always been at the heart of what we do, and by working directly with SEMA Garage, we’re making it easier than ever for their members to tap into that technology for real large-scale applications.”

    Jim Moore, the VP of OEM and Product Development at SEMA, said, “SEMA Garage is thrilled to partner with BigRep to bring large-format rapid prototyping into our Product Development service lineup. This cutting-edge capability gives our members the tools to stretch the limits of innovation and improve the speed and efficiency of their development process.”

    The BigRep STUDIO

    BigRep’s partnership with Legacy Motor Club was one of the most interesting use cases I wrote about last year, because it shed light on the fact that NASCAR teams are already using distributed AM to respond more quickly to constantly changing design requirements imposed by the stock car racing league. The partnership with SEMA Garage has the potential to do something similar for the entire automotive market, as BigRep now has a foot in the door of an enterprise with a reach of over 6,000 companies.

    Aftermarket parts that aren’t safety critical would seem to be a perfect middle-ground for scaling AM’s adoption in the auto sector. It addresses demand in a way that remains removed from any life-or-death hazards, targeting a demographic that by definition is willing to spend disposable income on pure enjoyment.

    That leaves 3D printing OEMs like BigRep relatively insulated from the cost and scrutiny of safety regulations, while still familiarizing auto part manufacturers with the underlying technology, letting both customers and enterprises experience the benefits of large-format AM firsthand. Simultaneously, BigRep is still making strides on the safety-critical side of the auto market at the pace required in order to meet regulatory requirements.

    It’s a winning strategy, and it’s one that other OEMs should flesh out further in other verticals where it already has a foundation. While there are plenty of examples, the first one that jumps to mind right now is the complementarity between targeting both the hobbyist and industrial drone markets at the same time.

    Images courtesy of BigRep

  • Stratasys Unveils 3D Printed Dental Anatomical Model Preset

    Stratasys has been working on digital anatomy for a number of years now. The company wants to make models that look and feel like the real thing. For doctors and dentists, this could mean more accessible testing. What’s more, applications in specific pathology, super rare cases, and lots of different parts can be made relatively inexpensively. This means that students could more easily get access to the rare, complex, and difficult.

    Digital anatomy replaces parts from animals, cadavers, or conventionally manufactured pieces. Cost is lower, overall training is less icky because you’re not experimenting on a body or dog mandible, and structures could closely resemble those that you will be dealing with in your practice. The company has been working for a few years on getting not only the look right through its PolyJet process, but also to get the feel just right. For your fingers, probes, and scalers, the tissue should feel just like the real thing. Ideally, Stratasys can give you a feel of that pathology so you’ll exactly know it for when you get to see and touch it in real people. Now, a 3D printed preset for dental will aid in this process.

    VP Medical at Stratasys Erez Ben Zvi said,

    “With this preset for dental anatomical models, we are entering a new segment of digital dental education and clinical simulation, helping customers move beyond traditional training methods toward more standardized, technology-driven learning environments. By combining anatomical realism with repeatability and customization, we’re enabling educators, clinicians, and device manufacturers to prepare for real-world procedures with greater confidence and consistency.”

    The preset can be used to make a wide range of anatomical structures. The company says that, “The models replicate the biomechanical behavior of bone, teeth, nerves, and soft tissue, providing realistic haptic feedback for drilling, cutting, suturing, and implant placement.”

    Trainers can use Cone Beam Computed Tomography (CBCT) scan information to make their own specific models. The CBCT scanner is that dental CT scanner that moves around your head while you bite down on a plastic bit. This kind of scan gives a 3D view of structures in your mouth, providing doctors with a far clearer picture of the actual situation in your head. CBCTs are especially useful in implants, root canals, and braces.

    Stratasys suggests that these models could be used for complex cases such as “atrophic jaws, sinus lifts, and bone grafting procedures,” as well as the more quotidian “tooth extractions, implant placement, periodontal surgery, endodontic surgery, and sinus augmentation.”

    Better cases, and more of them, can be a real driver for the adoption of this preset. The idea that at any given time, all your students can practice on the same complex case, for example, and then collectively share their experience, is very compelling. You could see a huge variety of shapes and pathologies as well. I’d personally work a lot better with a 3D printed model than a body or part of an animal. I also like that teachers can turn to cases they themselves have experienced as a learning tool. Maybe one type of root canal should not be done at all, or is so tricky that the patient should come back another time. This is the kind of situation that can be found in scans easily and then given to students.

    I don’t know if dentists feel that these models are accurate for them. Does it really feel like the human mouth does? Is the pass of your mirror over the gums the same? But if it comes close, then this can be a viable, less expensive training solution for dentists the world over.