• Controlled Powder Production for Advanced Research Applications

    Modern physics experiments and high-value industrial applications increasingly depend on custom, high-performance materials. These often require strict constraints such as radiopurity, controlled microstructure, and repeatable powder behavior in metal additive manufacturing. To expand its internal capability from design through production and validation, INFN LNGS developed the HAMMER Hub and integrated additive manufacturing with materials engineering, including lab-scale powder production for selected research needs.

    CHALLENGE

    INFN typically purchases metal powders from specialized suppliers, but certain activities require capabilities that are difficult to meet with standard commercial materials. This includes atomization from radiopure batches and exploratory alloy research, where rapid iteration on chemistry and powder morphology is essential. For powder bed fusion laser beam (PBF-LB), particle size distribution (PSD) is a key requirement, and the ability to validate powder behavior in-house supports process stability and part quality.

    INFN LNGS adopted the ATO Lab ultrasonic atomizer as a dedicated research tool within HAMMER to enable controlled powder production for selected, high-value use cases. The system is used to atomize materials from radiopure batches and to support new materials development by optimizing powder characteristics relevant to additive manufacturing, with a strong focus on PSD for PBF-LB. INFN is also preparing a new ATEX laboratory dedicated to the development of new materials for internal use and for aerospace-oriented research. In addition, an IMS module has been installed in the new area, further strengthening the overall process and materials workflow.

    With the ATO Lab in place, INFN strengthened its ability to synthesize and optimize innovative metallic materials for scientific and industrial use while maintaining tighter control over powder characteristics relevant to AM. INFN measured better powder sphericity with ATO Lab compared to commercial powders. The atomizer also expanded freedom to investigate tailored material routes under scientific constraints, with steels processed successfully (details restricted). Overall, the system established a solid foundation for ongoing and future research lines, supported by the ATEX expansion and the IMS module.

    By integrating ATO Lab into the HAMMER ecosystem at LNGS, INFN gained a flexible, research-oriented capability for powder production and alloy exploration, particularly valuable where radiopurity, PSD control, and rapid iteration are critical. The platform supports both internal scientific needs and technology transfer opportunities, with further growth enabled by the new ATEX laboratory and the ATO Induction Melting System (IMS), which expands the range of processable materials.

    About the Author:

    Arcway is a technology company advancing the integration of additive manufacturing into industrial and commercial production environments. By developing software and automation tools that connect design, engineering, and manufacturing data, Arcway helps organizations unlock the full potential of 3D printing across complex, regulated, and high-value applications. The company’s solutions support real-time decision making, streamlined workflows, and improved quality control for additive processes, making it easier for businesses to adopt and scale 3D printing technologies. Arcway’s platform is used by manufacturers in aerospace, defense, medical, automotive, and other industries where precision, traceability, and performance are critical.

    Arcway is a Silver Sponsor of Additive Manufacturing Strategies (AMS) 2026, a three-day industry event taking place February 24–26 in New York City. The conference brings together industry leaders, policymakers, and innovators from across the global AM ecosystem. As a sponsor, Arcway will support discussions focused on scaling additive manufacturing, industrial adoption, and emerging production technologies. Registration is open via the AMS website.

  • Takeaways From MILAM 2026: Defense’s Growing Role in Driving 3D Printing – Part II

    At the recent Military Additive Manufacturing Summit & Technology Showcase (MILAM 2026), additive manufacturing wasn’t just being discussed as a production strategy; it was being packaged for deployment. A big focus at the event was the need for additive systems that can operate in the field, not just inside traditional factories. Instead of relying only on centralized production, many companies are developing machines that can be transported, set up quickly, and used close to where parts are needed, including machines designed to fit on ships and systems meant to deploy with military units. Most of the people we talked to concur that if additive manufacturing is going to matter in defense, it has to be available where the work is happening and when parts are needed.

    What’s more, that idea showed up clearly on the show floor. Phillips Corporation brought its Phillips Additive Hybrid system, a large-format hybrid machine designed for deployment. The system is meant to support repair, sustainment, and part production in defense environments, including scenarios where access to traditional manufacturing infrastructure is limited.

    Phillips Additive Hybrid system at MILAM 2026.

    Brian Kristaponis, General Manager of Phillips Corporation’s Hybrid Division, and Derek Milgate, Sr. Marketing Manager at Phillips Corporation, said the strongest demand signal they’re seeing right now is deployable technology. Speed and cost still matter, but for defense customers, the priority is being able to set these systems up quickly and use them in the field. They explained that the goal is to cut setup times dramatically, moving from hours to something closer to minutes.

    Phillips already has systems operating on U.S. Navy ships, and its machines have also been deployed with military units during training exercises. In those settings, the benefit is simple: parts can be made or repaired on site, without waiting on long supply chains or outside vendors.

    “For defense, additive manufacturing is very valuable when it can be moved, deployed, and used where the need exists,” noted Kristaponis.

    Phillips Additive Hybrid system at MILAM 2026.

    Another example on the show floor came from ADDiTEC. The brand showcased its Hybrid X expeditionary unit, a self-contained system designed specifically for forward and field use. Speaking at the booth, ADDiTEC’s Electrical and Controls Engineer, Bryson Pender, explained that the system is designed for deployability and flexibility, combining additive and subtractive technologies on a single platform.

    Pender said the goal is to support spare parts and hard-to-source components, especially in environments where supply chains are strained. The system has already been deployed on a Navy ship, and ADDiTEC is working toward broader use in the field. By pairing liquid metal aluminum printing with laser wire DED, the machine can produce a wide range of parts, balancing speed for larger components with higher resolution where needed.

    For defense users, that flexibility is super important. As Pender described it, “systems like this are meant to go where the work is, whether on ships or in deployed settings, allowing parts to be made or repaired on site instead of waiting for replacements.”

    The Hybrid X expeditionary unit by ADDiTEC at MILAM 2026.

    The focus on deployable systems at MILAM reflects a broader trend across defense manufacturing. In recent years, the U.S. military has tested containerized additive units, expeditionary fabrication labs, and mobile repair platforms aimed at reducing downtime and supply chain risk in remote or contested environments. The systems on display in Tampa suggest that those early experiments are now becoming more standardized and commercially supported.

    Stratasys booth at MILAM 2026.

    Still, at MILAM, it was clear that speed alone isn’t enough for defense. Additive manufacturing also has to meet strict qualification requirements, which can later support adoption in other industries.

    Additive manufacturing is being used to reduce supply chain delays, especially for parts that are hard to source or take a long time to arrive. And making parts closer to where they are needed helps avoid long wait times and production backlogs.

    Stratasys‘ Vice President of Industrial Business, Foster Ferguson, noted that one of the biggest factors still slowing wider adoption is confidence in the qualification process, which continues to limit how quickly companies can scale production.

    “One of the biggest remaining bottlenecks is awareness and confidence in the qualification process, which continues to limit scalability across production applications.”

    Aerospace and defense, he continued, remain the strongest drivers of demand, as additive manufacturing becomes more closely tied to readiness, sustainment, and long-term production needs.

    Looking ahead, Ferguson said he expects deeper collaboration between industry and the Department of Defense to accelerate adoption.

    “By next MILAM, we’ll see early areas of a modernized defense industrial base where scalable production has been unlocked through AI-enabled workflows, automation, and qualified industrial systems,” said the executive.

    Phillips Additive Hybrid system at MILAM 2026.

    MILAM 2026 showed that deployable additive manufacturing is no longer experimental. Systems are already operating on Navy ships and alongside military units, and companies are designing equipment specifically for field use. As defense pushes for faster response times and shorter supply chains, additive manufacturing is being positioned not just as a production tool, but as a capability that can move with the mission.

    Images courtesy of 3DPrint.com

  • From Vision to Volume: The Next Chapter for Additive Manufacturing

    Additive manufacturing has spent years navigating skepticism, hype cycles, and industrial validation. Now, the industry finds itself at a decisive turning point. The conversation has shifted away from futuristic possibilities and toward reliable, repeatable, economically viable production. For Carbon CEO Phil DeSimone, this shift from experimentation to everyday manufacturing represents the most meaningful evolution yet, and the current momentum signals that the technology is moving from promise to real-world impact.

    A Sector That Has Quietly Come of Age

    When I first entered the industry more than a decade ago, AM was often framed as a disruptive force positioned to overturn traditional manufacturing overnight. As we now know, that moment never arrived, but something more valuable did. Through steady advancement, the technology has matured into a dependable tool for producing final-use parts across a growing range of industries.

    Today, AM is delivering tangible, everyday impact. 3D printed products are improving people’s lives every day – custom dental solutions, advanced seating cushions for wheelchair users, high-performance industrial components, and performance footwear are now part of routine production cycles, not prototyping or conceptual showcases.

    In industries like MedTech, long-term investment is paying off. Applications developed years ago are now achieving regulatory certifications, validating AM’s suitability for precise, safety-critical products coming directly off production printers. While these may be produced at lower volumes, they benefit from far greater design freedom, production speed, and performance. This marks a pivotal shift away from AM as a novelty to a proven manufacturing strategy.

    Carbon Keystone dental model. Image courtesy of Carbon.

    The Perception Problem That Still Needs Solving

    Despite these developments, lingering misconceptions remain. Many established manufacturers still associate 3D printing with prototyping rather than production. Closing this perception gap means more than showcasing clever design possibilities. It requires demonstrating consistency, material reliability, and process reliability — qualities traditional manufacturing has refined for decades. This is particularly crucial in regulated sectors, where trust must be earned through measurable, validated performance.

    AI and Automation as Catalysts for the Next Wave

    Alongside advances in hardware and materials, AI and automation are rapidly reshaping AM workflows. Automation is already being applied meaningfully, where repetitive tasks can be offloaded to software so that employees can focus on higher-value tasks.

    However, the most transformative impact will unfold in design. Creating optimized geometries for AM, particularly lattice structures, has historically required specialized knowledge. By embedding manufacturing intelligence directly into design tools, AI could remove one of the industry’s biggest bottlenecks — the steep learning curve of designing specifically for additive. This would result in faster development cycles, more functional products, and a broader base of designers capable of leveraging AM.

    Carbon dental lab. Image courtesy of Carbon.

    Rising Expectations and a Redefinition of Value

    As AM has matured, customer expectations have evolved. Reliability is now fundamental. Companies want assurance that a printer fleet will deliver the same results each time, regardless of scale or location. Ultimately, customers are looking for end results, which is why the 3D printing process must be viewed simply as the enabler rather than the end goal.

    While cost has historically been cited as a barrier, economics improve considerably when AM systems are tuned for the specific application. Working closely with customers to co-develop the right materials, workflows, and geometry can unlock both performance gains and really competitive unit economics. We’ve seen this firsthand, where Carbon 3D printed shoes and midsoles now feature on both high-end catwalks and the high street, with partnerships with the likes of adidas and Alexander Wang. This extends to other areas, like sports protective equipment, where 3D printed helmet liner components are more commonplace, having advanced from the professional level into college and now even high schools with partners like Riddell.

    A More Mature, More Realistic Market

    This year promises to be more defined by substance than spectacle. The most important developments will center on scalable, profitable, and dependable applications that are worth integrating into everyday manufacturing. These applications will help AM continue to earn its place in the mainstream.

    Consolidation will likely continue due to the fundamental challenges of AM as a capital-intensive market, and the complexities of each different hardware and material. The remaining players will be larger, more mature, and focused on sustainable value creation rather than small wins. Success will come from the utilization of 3D printing, not just printer deployments, making working with brands and OEMs to solve real problems and bring differentiated products to market more valuable than ever.

    Phil DeSimone. Image courtesy of Phil DeSimone via LinkedIn.

    About the Author:

    Phil DeSimone is a materials and additive manufacturing expert at Carbon, where he leads initiatives in advanced polymers and industrial applications for 3D printing. With deep technical experience in developing high-performance materials and scaling them for commercial use, Phil bridges the gap between innovation and real-world production challenges. His work focuses on helping manufacturers across industries unlock the full potential of additive technologies. Outside of Carbon, he regularly contributes insights on material science, sustainable manufacturing, and digital production trends to industry publications and events.

    Carbon will participate in Additive Manufacturing Strategies (AMS) 2026, a three-day industry event taking place February 24–26 in New York City. The conference brings together industry leaders, policymakers, and innovators from across the global AM ecosystem. On February 26, Phil DeSimone, CEO of Carbon, will take part in a special presentation titled “The Only Best Answer: 3D Printing for Helmets in the NFL and Beyond.” 

  • Creative Destruction in AM: What the Nobel Prize Winners Got Right

    When the Nobel Prize in Economic Sciences was awarded in 2025 for work explaining innovation-driven economic growth, many readers outside economics likely skimmed past it. Inside manufacturing and technology circles, the reaction was equally quiet. Yet for anyone who has followed additive manufacturing (AM) closely over the past two decades, the prize landed comfortably close to home.

    The awarded work formalised a mechanism first articulated by Joseph Schumpeter: creative destruction. Innovation creates temporary advantage, displaces established structures, and reallocates value. Growth emerges not from smooth optimisation, but from discontinuity. In the 1990s, this intuition was turned into a rigorous growth model by Philippe Aghion and Peter Howitt. In 2025, it was recognised as one of the central explanations for long-term economic development and awarded the Nobel Prize in Economic Sciences.

    Additive manufacturing has often been framed as disruptive, even though the term creative destruction has rarely been used explicitly. AM disrupts manufacturing. AM replaces supply chains. AM kills machining. Anyone with practical exposure knows that this framing rarely survives contact with reality. Conventional manufacturing remains dominant. Capital stock persists. Qualification regimes endure. Machining is alive and well.

    Something interesting happens if the theory is applied carefully. In some well-known successful additive manufacturing applications, the mechanism described by Schumpeter and formalised by Aghion–Howitt appears almost uncomfortably precise.

    Additive manufacturing is not a single innovation. It is a collection of innovations operating under different constraints. In most of them, coexistence dominates. But in a few, AM introduces a capability shift that changes economics, collapses process chains, and renders prior advantages structurally weaker. That is not hype. That is creative destruction in the original sense.

    Consider medical implants. Orthopaedic implants have long been manufactured at scale using established methods. Those methods are not inherently inadequate. However, clinical performance in some implant categories benefits from controlled porosity, lattice structures, and surface architectures that encourage osseointegration. Conventional manufacturing can approximate these features, but often only by adding steps such as coatings, assemblies, secondary treatments, or by accepting design compromises.

    Metal powder bed fusion changed that balance. In these specific implant classes, porous structures are no longer applied to a part; they are the part. The functional geometry becomes intrinsic. When this happens, entire sections of the legacy process chain lose relevance. Coating suppliers, intermediate processing steps, and certain qualification logics are displaced, not because AM is fashionable, but because the economic and functional centre of gravity has shifted.

    Having been directly involved in the early industrialisation of these processes, including introducing additive manufacturing into regulated serial production, this pattern is clear in hindsight.

    The value did not come from replacing manufacturing as such, but from enabling new products that made previously dominant process steps economically and technically secondary.

    Incumbent companies often survive these transitions by adapting. What tends to disappear is not the company, but the basis on which it previously competed. Startups and new entrants often introduce the initial shift, while established firms adapt to it. Innovation rarely removes firms. It removes the conditions that made certain capabilities valuable.

    A similar pattern appears in tooling, although it is quieter and easier to miss. Here, additive manufacturing does not replace tooling, but alters the economics around it. In early and intermediate stages, faster feedback, shorter time to market, and improved economics for low-volume manufacturing weaken the advantage of long, rigid tooling pathways in favour of more flexible ones.

    Tooling as a discipline does not disappear, and machining remains essential. What changes is where the advantage resides.

    These cases are striking because they align so cleanly with the theory. They also highlight something equally important: many of the most visible AM success stories are better described as creative creation than creative destruction.

    Clear aligners are a good example. Their rise is often described as a manufacturing story, but the primary innovation is systemic. Digital scanning, treatment planning software, data-driven workflows, and large-scale custom production were combined into a coherent pipeline. Additive manufacturing plays a crucial enabling role, but it does not primarily displace an existing manufacturing process. It enables a new operating model and a new market category.

    Rather than replacing an established structure, a new one emerged.

    The same pattern is visible in rocket engines and propulsion development, but here the effect goes well beyond faster iteration. Additive manufacturing expands the feasible design space itself. Deeply integrated geometries can be treated as a single design problem rather than as a sequence of manufacturing compromises. This has enabled propulsion architectures that would be difficult to produce, qualify, and iterate using conventional fabrication routes, while maintaining comparable mass, cost, and reliability.

    Recent engine programs, including the latest generation of SpaceX engines, illustrate how part count reduction and internal geometric freedom translate into higher performance, improved robustness, and faster system-level maturation.

    A complementary signal can be seen with LEAP 71. Here, new propulsion concepts are not derived by iterating existing designs, but by combining multiple innovations and generating broad solution spaces computationally, which can then be built and tested directly using metal additive manufacturing. This shifts established design paradigms rather than refining them.

    From an economic perspective, the interest lies in how innovation is created. Advantage no longer comes from incremental optimisation of known designs, but from access to a design method that makes previously infeasible solutions economically testable. In that sense, the example aligns closely with the mechanism recognised by the Nobel Prize, where innovation changes what can be explored and therefore what can compete.

    Taken together, these cases show that in the new space sector, additive manufacturing both changes how fast hardware is developed and what kinds of systems can be developed in the first place. It helps explain why new space provides a particularly clear example of how additive manufacturing aligns with the innovation mechanism recognised by the Nobel Prize, where new capabilities reshape both performance outcomes and sources of advantage.

    This is not creative destruction in the narrow sense, but creative creation. A new development regime becomes viable through a change in production capability.

    A different but very strong signal comes from consumer electronics, where Apple has publicly adopted metal additive manufacturing for the serial production of titanium watch cases. The significance lies in the context. Additive manufacturing is now being trusted in settings where volume, consistency, and brand risk are decisive.

    Stockholm city. Image courtesy of Stockholm city.

    The Nobel recognised theory is not challenged by the different patterns observed across additive manufacturing applications. It is corroborated by them. Creative destruction was never meant as a universal description, but as a mechanism that operates under specific conditions. Where those conditions are present, the outcomes follow a familiar pattern.

    Seen this way, there is no need to describe additive manufacturing as disruptive in general. What matters is where specific capabilities change design choices, production routes, and cost structures. In those cases, established advantages weaken, and value shifts accordingly.

    The work recognised by the 2025 Nobel Prize in Economic Sciences, awarded to Philippe Aghion, Peter Howitt, and Joel Mokyr, is an attempt to describe how innovation reshapes economic structures when specific conditions are met. Seen through that lens, it becomes clearer where and why additive manufacturing changes who wins and why, and where it does not.

    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.

  • Formlabs Board Joined by Rob Willet

    CAD and 3D printing veteran Carl Bass is to leave Formlabs‘ board after eight years. Formlabs Board Chairman Natan Linder said,

    “Formlabs also announced that Carl Bass will step down from the Board following more than eight years of dedicated service. Bass joined the Formlabs Board in 2017 and has played a significant role in helping the company redefine additive manufacturing. Carl has been an extraordinary partner to Formlabs. He brought strategic clarity, bold ambition, and deep empathy for builders and designers. We’re deeply grateful for his leadership and the lasting impact he has made on the company.”

    The former Autodesk CEO will be replaced by Rob Willett. Rob Willett is the former CEO of the Cognex Corporation, a machine vision company with $875 million in revenue that makes tools for semiconductor manufacturing, barcode scanning, OCR, and defect detection.

    Formlabs premium teeth resin. Image courtesy of Formlabs.

    Machine vision is an adjacent industry to 3D printing, and on desktop Material Extrusion, we can see that machine vision has helped usher in a revolution. Machine vision is used for more accurate extrusion, deposition, and intra-layer bonding. Perhaps Formlabs could use some of that to improve its own printers. More probably, however, they’re looking for executive guidance and experience to bolster growth and a possible IPO.

    Rob Willett. Image courtesy of Cognex.

    Willet says that,

    “Formlabs has built an industry-leading platform at the intersection of manufacturing hardware, software, and materials,The company is uniquely positioned to drive the next era of digital production by making powerful fabrication tools more accessible without sacrificing performance. I’m excited to join the Board of Directors and help guide the company as it continues to scale globally.”

    Formlabs Board Chairman Natan Linder believes that,

    “Rob has built and scaled global industrial technology businesses with operational rigor and discipline, There is a strong MIT-rooted heritage connecting Cognex and Formlabs, two companies built at the intersection of software, hardware, and manufacturing. As Formlabs continues its evolution from breakthrough startup to enduring manufacturing platform, his experience scaling complex hardware and automation companies will be invaluable.”

    Formlabs is evolving. The company was once a one-technology, essentially one-integrated-product company centered on founder Max Lobovsky. Now with many more materials, printers for specific applications, sintering, and more complexity overall, the firm is becoming larger and more complex. It has many more products to support, many more interactions and dependencies, more departments, and more people to manage. The more complex beast is still formidable. It puts out an excellent series of products that work well. Sintering systems have teething problems but are now showing maturity. The SLA systems have always been good and have improved, getting much bigger and more sophisticated.

    Formlabs is now faced with a choice to specialize in more sectors within SLA and sintering and make more application-specific solutions, or to expand in other ways. Expanding in other ways could be a choice to ship more automation, workflow, and organizational software, becoming the software partner for many manufacturing businesses. This is less strange than it sounds. Many of its clients only run CAD and Formlabs software, while many others have lots of different 3D printers from different brands and a balkanized mess of other PLM and other packages. Other clients are small and want something specific for a two-person team or a design-led lamp company with five employees. There is no real good solution for these people, and definitely not a good, inexpensive solution. Pivoting to become the connective tissue for manufacturing firms would be a strong move.

    Formlabs booth at MILAM 2026. Image courtesy of 3DPrint.com.

    Another play would be to develop desktop CNC, milling, and laser-cutting devices. These devices could gain ready commercial appeal and significantly broaden the firm’s offering. I’d probably advocate for a hybrid of both solutions. On the one hand, introduce a desktop water jet or similar while expanding the software to act like an MES, PLM, and print farm manager for Formlabs and other equipment. This seems like a logical extension of current capabilities, while serving customers it now has long-term relationships with. Either way, the big discussion in the boardroom is whether, in this current rollercoaster economy, going public is a desire or a need. This looks like an opportune appointment and a continuation of Formlabs’ march toward growth and perhaps an IPO.

  • 3D Printing Nerd Challenges Lawmakers to Visit a Working Print Farm Before Banning Tech

    Joel Telling asked politicians attempting to ban 3D printing in his home state to step away from their desks and come visit the farm. His 3D print farm, to be exact. Telling, known as the 3D Printing Nerd, is not only a popular YouTuber, but also an advocate for additive manufacturing in all its forms. Based in the Seattle, Washington area, his studio houses over 50 Prusa MK4S 3D printers used to manufacture parts for clients, from Halloween props to educational robotic kits.

    “Come see the print farm in action. Come learn what 3D printing actually is, what it can do, and more importantly, what it cannot do,” he said in a recent YouTube video.

    He is one of numerous makers taking to YouTube to raise the alarm about Washington State House Bills 2320 and 2321. The bills are intended to curb the illegal 3D printing of “ghost guns” and untraceable firearms, but may very well destroy the hobby of 3D printing, hamper the additive manufacturing industry, and make criminals of anyone holding digital files of firearm-related models.

    HB 2320 would prohibit the possession, sale, or distribution of “digital firearm manufacturing code” for anyone who is not a federally licensed firearms manufacturer. As currently written, the law would assume anyone caught with files for gun parts intends to distribute or illegally manufacture firearms. The law would also ban the sale of both 3D printers and CNC machines that are “primarily intended” to make firearms. Intention in this case could be as simple as allowing gun-shaped parts on a manufacturer’s file sharing site, such as MakerWorld for Bambu Lab or Printables for Prusa Research.

    HB 2321 would require any 3D printer or CNC machine sold or transferred to Washington state to have “blocking features” to prevent the printing of firearm components. The bill proposes a “firearm blueprint detection algorithm” that could detect firearm frames, receivers, or parts designed to convert a weapon into a machine gun. It would require all complaint 3D printers and CNC machines to be connected to the internet and monitored by a government website.

    While both bills are problematic, HB 2321 seems to have hit a snag. Experts agree that requiring a 3D printer or CNC machine to not print guns is akin to asking a toaster to not toast whole wheat bread. The machines are simply not smart enough to determine what they are printing. Instead, machines would need to be connected to the internet in order to pass files through a government sanctioned check point. This could involve checking Gcode against a list of known “illegal” files, using a state-approved slicer, or using your printer’s camera with AI detection.

    “An STL file is just geometry, a list of points in space,” Telling said. “A computer cannot look at a raw shape and know what it’s for. The same cylinder could be a movie prop or a mechanical spacer or a tool handle.”

    HB 2320, which could ban the sale of 3D printers in the state of Washington, has been fast tracked. On February 12, it was pulled from the Appropriation Committee and placed on second reading—the final stage before a floor vote—and could be voted on by the full house at any moment. The bill would still need to move through the Washington State Senate before becoming law.

    We asked Telling if any lawmakers have asked to come by for a tour. He told us that none have taken him up on the offer, even after sending the video directly to Representative Osman Salahuddin, who is the primary sponsor of the bills and a fellow resident of the Seattle metro area.

    Residents of Washington state can comment directly on these bills through the state website. These comments will become part of the official record.

    Comment on HB 2320

    Comment on HB 2321

    You can also respectfully voice your opinion directly to Rep Salahuddin via email: [email protected]

    Or mail:
    Representative Osman Salahuddin

    PO Box 40600

    Olympia, WA 98504-0600

  • In-Situ Automated Toolpath Generation and Auto-Alignment for Performance-Driven Directed Energy Deposition (DED)

    The evolution of Directed Energy Deposition (DED) systems has increasingly focused on improving process adaptability, geometric fidelity, and integration into automated manufacturing environments. FormAlloy has advanced this progression through the development of in-situ, automated toolpath generation combined with auto-alignment capabilities, enabling precise material deposition on both additively and traditionally manufactured components. These capabilities address longstanding challenges associated with geometric variability, part registration, and throughput limitations in metal additive manufacturing.

    Traditional DED workflows rely heavily on offline CAD models and pre-programmed toolpaths, assuming consistent part geometry and ideal fixturing. In practice, however, dimensional variation introduced during machining, casting, forging, or service wear often necessitates manual rework, reprogramming, or conservative deposition strategies. FormAlloy’s in-situ toolpath generation approach mitigates these constraints by incorporating real-time scanning and coordinate registration directly within the deposition cell, allowing toolpaths to be generated and adjusted based on the actual part geometry.

    FormAlloy’s DEDSmart® Path enables in-situ, automated alignment and toolpath generation

    In-Situ Toolpath Generation and Auto Alignment

    Central to FormAlloy’s approach is the ability to automatically align scanned part geometry to the machine coordinate system prior to deposition. Through the use of fiducial features, surface registration algorithms, and integrated sensing, the system establishes accurate spatial alignment without manual intervention. This auto-alignment capability is particularly critical in high-throughput environments, where minimizing setup time and ensuring repeatable deposition across large part volumes are essential.

    Once alignment is established, toolpaths are generated in situ to conform to the measured surface geometry. This enables deposition that is tightly coupled to the true part condition rather than an idealized model, reducing excess material, minimizing post-processing, and improving dimensional control. The closed-loop nature of this workflow supports consistent results even when parts exhibit batch-to-batch or part-to-part variability.

    Performance Enhancement in Consumer Goods Tooling

    In consumer goods manufacturing, tooling such as molds, dies, and forming tools are often produced using conventional manufacturing methods but experience localized wear or performance degradation during service. FormAlloy’s in-situ toolpath and auto-alignment capabilities enable selective deposition of high-performance materials directly onto these tools without requiring full remanufacture.

    For example, wear-prone regions of an injection mold can be scanned and automatically aligned, after which a toolpath is generated to deposit a wear-resistant or high-hardness alloy only where required. This approach allows manufacturers to enhance tool performance while preserving the bulk tool material and geometry. Because alignment and toolpath generation are automated, the process is compatible with production-scale workflows where rapid turnaround and repeatability are critical.

    In addition to repair, this capability enables functional enhancement, such as reinforcing edges, improving thermal resistance in high-heat zones, or modifying surface properties to extend tool life. The ability to integrate these enhancements into existing tooling workflows supports increased uptime and reduced total cost of ownership.

    Turbine Blade Enhancement for Energy Applications

    Energy-sector components, particularly turbine blades, present complex geometries and operate under extreme thermal and mechanical conditions. FormAlloy’s automated toolpath generation enables precise deposition on airfoil surfaces, leading edges, and blade tips by conforming deposition paths to scanned geometries. Auto-alignment ensures accurate registration between the blade and deposition system, even when blades exhibit distortion or service-induced wear.

    This capability allows selective addition of high-value materials—such as oxidation-resistant or high-temperature alloys—only in regions that experience the greatest operational stress. By minimizing the volume of expensive material used and maintaining aerodynamic fidelity, FormAlloy’s approach supports both performance improvement and cost efficiency.

    High-Throughput Integration and Manufacturing Implications

    FormAlloy’s X5R Machine boasts a 1.8m x 1.1 x 1.1m build volume

    The combination of in-situ toolpath generation and auto-alignment enables FormAlloy DED systems to operate effectively in high-throughput manufacturing environments. By reducing reliance on manual programming and accommodating part variability, these capabilities facilitate scalable deployment for both production and sustainment applications.

    As manufacturers seek to integrate additive processes alongside traditional manufacturing, FormAlloy’s approach demonstrates how DED can be used not only for part creation but also for targeted performance enhancement of existing components. This represents a significant step toward intelligent, adaptive metal manufacturing systems capable of meeting the demands of modern industrial production. And it aligns strongly with what customers are asking for now.

    As Melanie Lang, CEO of FormAlloy, puts it:

    “Across our customer conversations, the market pull is unmistakable: defense programs want resilient, qualified repair and sustainment at speed; energy operators want highertemperature performance and longer service intervals; and consumer goods manufacturers want faster tool modifications and more uptime. Insitu toolpath generation and autoalignment are what make DED practical at scale—because we’re no longer programming for an ideal CAD model, we’re manufacturing to the real part in front of us.”

    For more information, visit www.formalloy.com, or contact FormAlloy’s team of engineers at [email protected].

    At Additive Manufacturing Strategies (AMS) 2026, FormAlloy Co-Founder and CEO Melanie Lang will participate in a panel about “Really Big Parts for Energy” on February 25th. This session is part of the broader AMS 2026 conference, which brings together industry leaders, policymakers, and innovators from across the global AM ecosystem. Learn more and register here.

  • Harvard SEAS Engineers Develop 3D Printing Method for Soft Robotic Components with Programmable Shapes

    The world of soft robotics is still largely in its pure research phase, but the R&D landscape has started to produce examples of early-stage commercialization. Researchers have started to refine their focus towards the genuine advantages of soft robotics over their more rigid counterparts, and the open-ended design capabilities of additive manufacturing (AM) have been pivotal to this evolution.

    Not long ago, researchers from Harvard’s School of Engineering and Applied Sciences (SEAS) published a study in Advanced Materials detailing a novel process they developed, which relies on a rotating printer with a multimaterial nozzle. Users print a hard polymer shell first, then layer a gel-like polymer on top, resulting in a channel when the shell fully hardens, after which the softer substance is washed away.

    Once the end product is inflated, the built-in design (“programmed shapes”) fully emerges, yielding bio-inspired shapes whose production would otherwise require casts and molds. Some of the example patterns detailed in the Advanced Materials article include flowers and human hands, addressing one of the most intractable problems associated with design for the robotics industry.

    Image-based print-path planning for generating complex soft robotic matter

    The researchers completed their work in the lab of Jennifer Lewis, Hansjorg Wyss Professor of Biologically Inspired Engineering at SEAS, who was the lead author on the first study based on the underlying process, published back in 2022. That earlier project demonstrated how helical shapes could be leveraged to make joints and hinges for soft robotics.

    In a press release about the study on using rotational multimaterial 3D printing to produce soft robotics components with programmable shapes, Jackson Wilt, a graduate student who worked on the project, explained, “We use two materials from a single outlet, which can be rotated to program the direction the robot bends when inflated. …In this work, we don’t have a mold. We print the structures, we program them rapidly, and we’re able to quickly customize actuation.”

    There are plenty of reasons to be optimistic about the long-term growth potential of the robotics industry, but I’m not sold on the near-term potential of the humanoid robots market, and I often wonder if humanoids have scalable commercial potential, at all. There just seem to be way too many obstacles — whether technological, economic, sociological, regulatory, etc. — standing in the way.

    However, I think that if the progress that’s being made in soft robotics can catch up to, and synchronize with, all the progress made thus far with more rigid robotics components for humanoid systems, the idea of a mass humanoid market at some point in the future starts to make more sense. This would extend the timeline for humanoid commercialization much farther out than the forecast of 2026 that some who are working on the problem have floated, though I don’t know if the people touting those forecasts can even believe them. But who knows what kinds of progress they’re seeing behind closed doors!

    In any case, I think the biggest selling point for the direction soft robotics R&D seems to be headed in, and the biggest selling point for the role of 3D printing in this research area, is the potential for maximizing functional design. The logical extreme for this would be typing in a desired function, and having a program respond with a design that fits the purpose, which is a concept that has attracted a significant amount of VC money in the last few years. Soft robots built with 3D printers could be a perfect use-case for testing all those text-to-design applications.

    Again, while I acknowledge that technological acceleration cares nothing for my feelings, I think that the mid-2030s “feels” like a more realistic target for meaningfully commercializing the sort of tech under discussion here. That may sound too slow to minds who seem to be itching for a singularity, but I think such minds have already been given far too much influence over the direction of human affairs.

    Images courtesy of SEAS

  • From Material Maturity to Fleet Execution: What Comes Next for Additive Manufacturing in the U.S. Navy

    Additive manufacturing is steadily moving from experimental use toward routine application in U.S. Navy shipbuilding, sustainment, and much more. In recent years, the Navy, working through its Maritime Industrial Base (MIB) Program in partnership with its technical community, has focused on a core challenge: how to introduce new manufacturing technologies without increasing technical, operational, or lifecycle risk. The answer is a disciplined framework called material maturity.

    Material maturity is the structured process by which the Navy rigorously classifies a material produced by additive manufacturing (AM) and characterizes its performance for comparison with similar legacy materials produced by casting or forging processes. Using this framework, material maturity teams have advanced candidate AM materials through an urgent focus on phased research, development, test, and evaluation. Early work in this space focused on feasibility and baseline characterization, relying on coupon- and block-level testing to establish fundamental corrosion resistance and mechanical properties. As programs progressed, testing emphasized robustness: understanding sensitivity to process variation, defect tolerance, post-processing effects, and long-term performance drivers.

    This work is leading to a significant milestone in early 2026: developing interchangeability guidance for the first two of nine planned additively manufactured materials: one metal using a laser powder bed fusion (L-PBF) printing process, and one using a directed energy deposition (DED) process. Interchangeability establishes that parts produced using these materials can replace legacy cast or forged components without affecting fit or function. In practical terms, from a fleet perspective, interchangeable parts simply install and perform as expected. As such, these parts won’t require additional engineering, waivers, or separate parts numbers.

    Importantly, material maturity has also demonstrated where adoption should pause. A third material studied under the program is not included in the early 2026 interchangeability guidance. This is because test specimens are not consistently meeting required performance thresholds. Though this delays adoption, it fulfills material maturity’s purpose: it identifies limitations early, protecting the fleet from premature use, and signaling to industry where further development is needed.

    Interchangeability does not represent the end of material maturity activities, but rather a transition point from technical validation to operational execution. From a logistics and acquisition perspective, this signals a new phase. With interchangeability guidance and supporting Military Performance Specifications (MIL-PRFs) in place, additive manufacturing advances from demonstration to procurable capability. Acquisition organizations can reference these as contractual requirements, enabling AM parts as authorized alternatives to legacy production.

    Logistics organizations must integrate this guidance into existing procurement and sustainment systems. This includes updating purchasing language, supply catalog references, and internal guidance, ensuring buyers know when and how to use approved AM materials. As a result, this integration supports one-for-one replacement, avoids redesign, and expands sourcing options. Put plainly, from a supply perspective, this opens up additional avenues of procuring parts without requiring any additional testing, waivers, or other barriers.

    The operational payoff is greater resilience. Approved AM materials allow multiple qualified suppliers to compete to supply parts for new construction and planned maintenance overhauls, reducing reliance on single-source vendors and cutting lead times with castings or forgings. For emergent repairs, additive manufacturing offers a solution when suppliers are unavailable or schedule is critical.

    For manufacturers, interchangeability guidance creates opportunity, but not automatic qualification. Suppliers seeking to parts must demonstrate compliance with the applicable MIL-PRFs. They’ll need to maintain auditable documentation to prove they are using pedigreed feedstock, have disciplined process control, and meet mechanical and corrosion requirements – in other words, that they’re following the Navy’s required processes, so the end product can indeed be trusted.

    Just as important, the decision to withhold the third material from initial interchangeability guidance sends a clear, constructive signal to industry. It demonstrates that inclusion in Navy guidance depends on proven performance, not aspiration. Manufacturers can invest confidently in approved AM materials and identify where further development is needed before scaling capability.

    Material maturity benefits both the fleet and the industrial base. For the fleet, it builds confidence in approved additively manufactured parts, ensuring they are safe, reliable, and supportable. For industry, it provides clarity on where investment aligns with Navy needs and where technical risk remains.

    Material maturity is intentionally conservative in its approach and forward-looking in its outcomes. By combining rigorous testing, formal specifications, and strict acquisition integration, it paves the way for additive manufacturing as a reliable, scalable part of naval shipbuilding and sustainment. Building on the current work, the foundation is laid for the responsible introduction of future materials and processes across the fleet, as additive manufacturing becomes a dependable Navy supply capability.

    Matt Sermon is Direct Reporting Program Manager, Maritime Industrial Base Program. In this role, he leads efforts to build needed capability and capacity in support of key Navy programs, advancing naval power through the largest Department of Defense industry revitalization plan since World War II. He oversees strategic initiatives in manufacturing technology advancement, workforce development, supply chain, shipyard infrastructure, and public/private partnerships—strengthening American industry to meet the growing demand for ships, submarines, and other maritime capability , ensuring long-term industrial readiness and national security.

    Previously, Mr. Sermon served as the Executive Director of Program Executive Office Strategic Submarines, where he provided executive leadership to the Columbia Class Submarine acquisition program and the In-Service SSBN/SSGN program. He was also assigned responsibility for revitalizing the Submarine Industrial Base, overseeing more than 250 acquisition personnel and managing approximately $130 billion in acquisition and sustainment programs. Before that, he served as the Executive Director for Program Executive Office Columbia Class Submarine and the Executive Director for the Amphibious, Auxiliary, and Sealift Office at Program Executive Office Ships.

    Mr. Sermon entered the Senior Executive Service in February 2019, and has been in federal service for more than 20 years. He has served in a variety of key leadership positions throughout his career, including Deputy Program Manager for the Columbia Class Submarine program (2016-2019), a $100 billion DoD Major Defense Acquisition Program. During his tenure, he led the program through detail design, construction readiness, and significant sustainment planning activities. Before leading the Columbia Class, he was the Deputy Program Manager for the Zumwalt Class Destroyer (2014- 2016) during test, trials, and delivery of the lead ship (DDG 1000). Prior to DDG 1000, he was the Deputy Program Manager for International Fleet Support in the Naval Sea Systems Command’s Surface Warfare Directorate (2010- 2014), where was responsible for the management of more than $5 billion in Foreign Military Sales cases for more than 40 partner nations.

    Other previous assignments include Principal Assistant Program Manager in the Support Ships, Boats, and Craft Program Office (PMS 325) in PEO Ships (2007-2010), where he led the $1.1 billion Egyptian Navy Missile Craft project while providing program management expertise for numerous other boat building projects.

    Prior to starting in Navy civilian service, Mr. Sermon was a U.S. Navy Surface Warfare Officer (Nuclear). He received his Surface Warfare Officer qualification aboard USS Ramage (DDG 61). Additionally, Mr. Sermon served as nuclear engineering officer aboard USS Dwight D. Eisenhower (CVN 69) before leaving the uniformed Navy in 2004. He is a veteran of Operations Enduring Freedom and Iraqi Freedom.

    Mr. Sermon is a member of the Acquisition Professional Community and has a Level III Certification in Program Management. He holds Defense Acquisition Workforce Improvement Act certifications in Production, Quality, and Manufacturing and Test & Evaluation, and has completed certification as a Project Management Professional (PMP). He received a Bachelor of Science degree in economics from the United States Naval Academy in 1999, and a Master of Science degree in engineering management from The Catholic University of America in 2006. He is a 2012 graduate of the Defense Systems Management College’s Program Manager Course. During his distinguished federal service career, Mr. Sermon has received three Navy Civilian Meritorious Service Awards and one Navy Civilian Superior Service Award. In 2023 he was named a Presidential Rank Award Distinguished Executive.

    At Additive Manufacturing Strategies (AMS) 2026, Mr. Sermon will present a talk about “AM for the Marine Industrial Base: Updates & Outlook” on February 24th. This session is part of the broader AMS 2026 conference, which brings together industry leaders, policymakers, and innovators from across the global AM ecosystem. Learn more and register here.

  • Velo3D Becomes First Qualified AM Vendor for US Army’s Ground Vehicles Program

    One indicator that I’ve used to help me track the additive manufacturing (AM) industry’s progress in terms of its technical maturity is the relative progress that each U.S. military branch is making in its AM capabilities when compared to the other branches. It would be difficult to quantify this with any single metric, other than perhaps the total mass of parts printed by each branch, and since we’re not really privy to that information, figuring it out is a mostly subjective analysis based on qualitative signs of technological parity.

    Usually, when I bring this up, it’s when I’m writing about the U.S. Army, and the current post is no exception: Velo3D recently announced that the U.S. Army has selected the company as the first AM vendor supporting the U.S. Army’s Ground Vehicle Systems Center (GVSC) in its activities related to accelerating AM qualification. This follows Velo3D’s announcement in early January that the company had reached a Cooperative Research & Development Agreement (CRADA) with the U.S. Army DEVCOM GVSC.

    That CRADA deal was the second with a U.S. military agency that Velo3D has signed in well under a year, the first being an agreement announced in Q2 2025 with the U.S. Navy to characterize materials primarily for Navy aerospace applications. Similarly, Velo3D will validate “complex parts and assemblies” for GVSC made from Aluminum CP1 and Inconel 718 on the Sapphire family of metal AM systems. The final parts, once validated, are ultimately destined for U.S. Army Tank and Automotive Command (TACOM).

    According to Velo3D, the company “met all GVSC qualification criteria” in under two weeks, hinting at the extent to which the U.S. Army is prioritizing a ramp-up of its AM capacity. While there’s no word yet on what parts exactly Velo3D will be producing for GVSC, there is at least one Velo3D user that has reported using the company’s machines for automotive tooling in the past.

    In a press release about the U.S. Army GVSC selecting Velo3D as its first qualified AM vendor, Brandon Peter, Associate Director for GVSC Materials Engineering, said, “Accelerating AM solutions is a critical effort for the Army and the GVSC. Velo3D has the advanced AM technology we need within industry and the robust process, quality and material data available required to support our accelerated qualification process. We are excited to replicate this process with other industrial base partners and appreciative of Velo3D’s close cooperation that enabled us to rapidly validate this concept.”

    The CEO of Velo3D, Dr. Arun Jeldi, said, “Velo3D is humbly honored to support the U.S. Army and be the first of an important cohort of industrial base partners facilitating GVSC’s rapid advancement of sustainment technologies at the speed of war — soldiers should expect nothing less from a company like ours. Our Rapid Production Solution is a proven solution the Department of War and the broader national security community increasingly rely on to accelerate the delivery of critical advanced technologies.”

    I brought up technological parity, and its relevance in an AM context to the U.S. Army, at the beginning of the post because this deal serves as a major signal that the U.S. Army — more or less the last domino in the Pentagon’s AM supply chain — is starting to approach parity with the Air Force and the Navy. This doesn’t mean that the Navy is “doing as much” in AM as the Air Force is, or that the Army is doing as much in AM as the Navy is, but that all three branches are now speaking the same language, so to speak.

    That’s significant if you believe, as I do, that cross-branch AM cooperation is an all-important prerequisite that the U.S. military must fulfill in order for its AM activities to truly hit critical mass. To put it in practical terms, the Navy’s ability to print parts all over the world, even on a deployed aircraft carrier, will be most valuable once the other branches have some baseline catalog of parts qualified on the platforms that the Navy uses.

    This is also why it matters that companies like Velo3D are reaching the same deals with one branch that they’ve already reached with another branch. More broadly, we can extrapolate out that same logic and apply it to the civilian sides of the dual-use spheres that the Air Force, Navy, and Army represent on the defense side.

    All the context here similarly highlights the importance of organizations like the National Institute for Aviation Research (NIAR), to which the DEVCOM GVSC awarded $100 million in 2023 and Velo3D sold a Sapphire 1MZ in 2024. The more AM cross-pollination there is between strategically critical sectors, the better chance AM has to genuinely contribute to supply chain resilience.

    Images courtesy of Velo3D