My Printer

  • Benelli Looks to 3D Printing for Gun Chassis

    There’s a lot happening in the world of 3D printing guns. There is the ever-present danger of some people trying to print guns at home. Suppressors are one of the largest 3D Printing applications, while on the Ukrainian battlefield, modifications are improving weapons. Firms are also using additive to make gun accessories such as cable covers, mounts, and the like. Whereas now most of the major gun manufacturers are making or selling 3D printed suppressors, they have been rather aloof toward 3D printing. This also aligns with recent Additive Manufacturing Research findings, which point to suppressors as one of the most commercially significant applications for metal AM, with demand driven by regulatory changes and broader adoption. The lion’s share of 3D printing innovation has instead come from small startups. This is something we see in cycling as well. In consumer-facing industries that traditionally handle most of their own subtractive manufacturing, we typically see greater hesitation to adopt 3D printing than elsewhere.

    This may be about to change. In golf, we can see how, years ago, every major golf firm toyed with ultra-high-end 3D printed clubs. These supercars (or superclubs) were meant to slather the brand with an engineering halo. It then took years for one of them, Cobra, to take this further and make more accessible clubs. As a path to adoption, I like it a lot. Rather than fighting in the trenches for years inside firms to secure adoption and overcome institutional resistance, we test it out in a limited production run, in a manageable, outsourced capacity. No one loses their job, and we all get pats on the back.

    It seems Benelli is on the same path, which could indicate that many major gun manufacturers may follow suit. Benelli is an Italian gun manufacturer that is particularly strong in shotguns. Benelli is part of Beretta Holding, a $1.4 billion firm that owns the storied Finnish gun manufacturer Sako and the optics firm Steiner.

    Beretta Lupo Alpha LE rifle featuring a lightweight, lattice-style stock design and 3D printed parts.

    Last year, the company released a Lupo Alpha rifle with 3D printed components. Now, an updated Lupo Alpha Limited Edition is said to be an ultralight, limited-edition rifle chambered in .308 Winchester, retailing for €10,000. A previous 3D printed version sold 1,000 units. At that point, the gun is squarely aimed at collectors. Most collectors collect elaborately embellished, traditionally made shotguns, including the ones from Beretta-owned Holland & Holland. These rarefied weapons are steeped in tradition and presented as heirlooms. But there is a new tech-savvy collector who wants something else.

    In this case, it’s super-light 3D printed furniture. The gun’s chassis is 3D printed. Removing weight while maintaining rigidity is the main driver here. The stock has also been designed using FEA and other digital tools to be optimized for specific stresses that the rifle will go through. The rifle barrel has been made with Electrochemical Machining. This is something we’re hearing more about, and rifle makers are pointing to this manufacturing method as a way to make better barrels as opposed to hammer forging and other traditional methods.

    In this case, the firm goes further and says it has its own electrochemical rifling process as well as BE.S.T. (Benelli Surface Treatment). BE.S.T. is an in-house Benelli-developed surface treatment that combines Physical Vapor Deposition (PVD) and Plasma Enhanced Chemical Vapor Deposition (PECVD) to make a super-hard, corrosion and abrasion-resistant coating for triggers, barrels, and more components. Barrels are also placed in a vacuum furnace and cryogenically treated. This kind of tech sell is especially useful for Benelli, which has only been making rifles for a few years and primarily makes shotguns. Being the new kid on the block, embracing technology and newness really is a way to position yourself as the challenger brand that rewrites the rules. That can be very effective marketing in a sector dominated by stalwarts; you substitute “tried and trusted” for boring and old.

    Roberto Massarotto, Marketing, Communications, and Product Director of Benelli, said that,

    “Additive manufacturing is something very important for us, we have some machines in the company, and we’re the only company that are able to produce in a massive quantity, these kinds of components, usually most companies use 3D printing for prototypes, we’re using it for production, its a different approach, 100%. This kind of shape, is impossible to get with any other kind of machining.”

    It’s interesting to see Benelli move ahead with polymer 3D printed stocks and chassis components. The firm got an Additive Manufacturing department in 2023, then consisting of Ultimaker and Stratasys machines. We’re unsure which technology or printers the company is currently using for production. Something like 3NTR would make a lot of sense. The fellow Italian firm is a few hours away by car and makes solid Material Extrusion machines. Some high-performance PPA GF type materials could really work as rifle barrels. With the right finishing process, this could work and would lead to a wider material range.

    Handling of the Beretta Lupo Alpha LE rifle featuring 3D printed parts.

    On the other hand, parent Beretta uses Powder Bed Fusion, running metal and polymer machines from EOS at its site. Beretta uses PA GF powders. Vat Polymerization has traditionally been used a lot in prototypes for stocks and the likes, but I’m guessing that we’re not there yet, performance-wise. The initial 3D printed version of the Lupo Alpha (the image at the top of the post) rifle looks like it is Powder Bed Fusion GF, but this one of the Lupo Alpha Limited Edition looks distinctly like vapor-smoothed Material Extrusion.

    Up close of the Beretta Lupo Alpha LE rifle with 3D printed parts.

    Given that the firm first sold a run of 1,000 3D printed guns and now sells 100, we can see that these small, profitable series are going ahead apace. But will this lead to 3D printed stocks & chassis becoming more common? Eventually, it might. I personally believe more in 3D printed custom cheek pieces and buttstocks. You could get a real improvement here in comfort and precision if you customized these to anatomy and behavior. If we look at Magpul’s success, an independent 3D printed stock or other component provider could also do well. We would expect more companies to look at polymer 3D printed accessories and stock them in the future.

    Images courtesy of Beretta

  • ExOne + voxeljet Are Trying to Do the One Thing Customers Need Right Now: Keep Machines Running, and Rebuild Confidence

    For years, ExOne and voxeljet were two of the best-known names in binder jet 3D printing, especially in sand printing for foundries. But in recent years, ExOne “got buried” inside Desktop Metal, as ExOne CEO Eric Bader put it, and customers started to worry about the basics: Who do I call? Will I get spare parts? Will service disappear?

    In an interview with Bader and co-founding Managing Partner at Anzu Partners, Whitney Haring-Smith, the message was that the companies are being brought together in a way that makes support stronger, and this is meant to be the start of a more public, more active ExOne again.

    Stabilizing Support

    The clearest “news” is that ExOne and voxeljet are now combining their aftermarket service and support operations into one coordinated global network, and they are making that the priority of the integration.

    Bader said, “The decision was urgent because there are close to 500 installed machines in the field, and customers need to know there will be no disruption.”

    Haring-Smith described the combined service team as an immediate upgrade for customers: “They now get roughly double the technician coverage, and those technicians are not new hires. Many have deep experience. Service technicians in general, on average, have a decade of experience, and some of them have more than two decades.”

    Just as important, Haring-Smith said they kept the service technicians they wanted to keep during the integration. That’s a big signal to customers that “the support structure isn’t being hollowed out.”

    ExOne facility in Gersthofen. Image courtesy of Ehret+Klein AG/ExOne.

    A “fresh air” moment after a chaotic year

    During our conversation, the executives addressed a concern many customers have raised this year: whether their machines will continue to be supported as the companies merge and restructure.

    “With so much consolidation, customers have been nervous about uptime, service, and parts. The Americas were especially urgent because many ExOne customers had been dealing with the turmoil around Desktop Metal,” stated Bader. “voxeljet already had a functioning service base outside Detroit (Canton/Detroit area), and ExOne can now ‘hook on’ to that structure to restore consistency. We can start spare parts once again, we can make service calls from there.”

    That’s the core theme for the consolidated company: stability first.

    How Anzu fits in and why that matters

    The duo also clarified how the company is organized following this year’s acquisitions. According to Haring-Smith, Anzu is now the investment firm behind ExOne. He described Anzu as a firm with about $1 billion in assets and 40–50 portfolio companies, and said ExOne is one of those holdings.

    He also highlighted a question customers often ask: “How long are you going to be here?” To which Haring-Smith answers, “Anzu holds ExOne in a fund with a long runway. We hold this in a fund that stretches into the 2030s, so we’re focused on building a company that is an enduring partner for our customers.”

    Basically, they want the market to understand this is not a “short-term flip” and not a “keep it quiet” asset like it felt under Desktop Metal.

    R&D is staying, and it’s getting bigger

    Beyond service, both executives also pointed to “innovation as a second pillar of the combined company.” They said the R&D leaders from both organizations will continue in the new structure: Andy Vardaman, who leads R&D at ExOne, and Alfred Breer, head of R&D at voxeljet. Haring-Smith described technology innovation as “at the heart of both companies.”

    Meanwhile, Bader added that the real opportunity is the knowledge built up over more than 20 years, and the best part is that now the teams can actually share what they know: “You see them now exchanging, seeing the opportunities, one can use what the other department developed and vice versa. More importantly, the combined R&D group will be larger than either company’s R&D team was on its own.”

    ExOne's sand 3D printing process.

    ExOne’s sand 3D printing process. Image courtesy of ExOne

    Looking ahead to 2026, Haring-Smith said the company is focusing on three main areas. The first is speed, both in terms of machine performance and how quickly customers can get service and spare parts. The second is local support. The goal, he explained, is to make sure customers can get help in their own region, whether they are in Asia, Europe, or the United States.

    The third focus is to continue pushing binder jet technology forward. Both companies have long histories in the space, and the combined R&D teams are expected to play a major role in developing the next generation of the technology. More details about that roadmap, they said, will come in future announcements.

    Bader added that the integration work is still underway internally. For now, the focus is on aligning teams and priorities so the company can move forward with a clear strategy. More specifics about the plan, he said, should emerge in the coming weeks.

    Where they think binder jet still wins

    Bader also pointed to where binder jet is already widely used today, noting that many of its strongest applications are not the high-profile metal stories that often dominate the conversation.

    He pointed in particular to binder jet printing for sand molds and cores used in casting. He said the technology has already been widely used in production for many years, especially in the foundry industry, where it is used to make parts in real manufacturing environments rather than just prototypes.

    He also noted that new opportunities are emerging beyond traditional automotive applications. Industries such as aerospace, energy, pumps, and defense are increasingly exploring the technology, especially for lightweight parts and efficiency improvements. Even a small improvement in something like a pump, he explained, can lead to significant energy savings over the lifetime of the equipment.

    The “preview” they teased but didn’t fully reveal yet

    The executives also suggested that more updates are coming very soon. Haring-Smith said the company plans to share additional announcements in the near future as the integration progresses.

    For now, the focus is on bringing the two organizations together and stabilizing operations. More details about the company’s structure and technology roadmap are expected in the coming weeks.

    Eric Bader will take on the position of CEO of ExOne Global Holdings and Rudolf Franz will join the supervisory board going forward. Image courtesy of voxeljet via LinkedIn.

    For ExOne and voxeljet, the immediate priority is to rebuild confidence with customers and strengthen support for the machines already running in the field.

    After a turbulent year across the AM sector, the companies are trying to make customers know that the service teams are in place, the global network is expanding, and the focus is now on moving the technology forward together.

    As Bader and Haring-Smith summed it up, the success in 2026 will come down to delivering for customers, which means faster service, faster machines, and stronger value overall.

  • CNC Kitchen Vibe-Coded a Texture Tool, then Gave It Away for Free

    Stefan Hermann, the creator behind the popular CNC Kitchen YouTube channel, wanted a better way to add custom textures to his 3D models. Although fluent in CAD, he found Blender, the software best at redesigning a mesh, too frustrating to learn quickly.

    “My mind was trained on parametric CAD, and I find it really hard to get into,” he admits. “I opened it, watched half a UV unwrapping tutorial, got completely lost, and closed it again.”

    So Hermann did what any resourceful engineer does these days: he vibe-coded his own solution. The resulting app is called “BumpMesh” and is a surprisingly powerful web-based tool specifically for applying displacement textures to 3D prints.

    Go Beyond Fuzzy Skin

    Adding textures to your 3D print isn’t just about the aesthetics. Though it can be useful for hiding seams and layer lines, strategically placed textures can add a grippy surface to things like printed handles. Textures aren’t normally available in CAD software, which leaves engineers who don’t master artistic tools stuck with only one option: adding “fuzzy skin” in the slicer.

    BumpMesh addresses the problem by allowing users to upload any model as an STL, OBJ, or 3MF file, then apply textures derived from grayscale images. The tool offers several patterns to start, plus you can upload your own custom textures.

    We Tested BumpMesh

    I uploaded a simple frog model from Thingiverse to BumpMesh. I wanted to dress him in a sweater, but I wanted something different from the default knit pattern.

    Creating a custom texture only requires a tiny bit of graphic arts skill. I used a screen grab of a sweater pulled from a shopping site, cropped in tight on a few inches of the pattern, then removed the color and made it high contrast. This pattern looked good on the screen, but after printing out on a Bambu Lab H2D using a .16 layer height, the results were blurred and indistinct.

    I was able to solve this by converting the image to a line drawing, which I touched up in Photoshop. This second frog had a much crisper faux sweater.

    Line drawings are better for creating new textures.

    The tool allowed me to paint the new knit texture onto Fred the frog, freeing his head and feet from the pattern to create a faux sweater. The paint tools are rudimentary, but pretty good considering this was coded in a week with AI.

    BumpMesh gives the user sliders to scale the pattern, rotate it, smooth it, change the projection mode, and adjust the texture’s depth. Want the texture to go inward or outward? A quick toggle for “symmetric displacement” handles that. The app gives real time feedback to assess your results.

    BumpMesh offers several powerful features that set it apart from simple slicer tools:

    • Multiple Projection Modes: Whether you’re texturing a cube (Triplanar), a bottle (Cylindrical), or a flat surface (Planar), BumpMesh ensures the texture wraps accurately around your geometry. 
    • Angle Masking: Automatically prevents textures from being applied to surfaces at a specific angle, which is crucial for maintaining a flat bottom face for better print bed adhesion or for ensuring shallow overhangs print cleanly.
    • Surface Masking (Paint-on): This is where BumpMesh truly shines. You can use a digital brush or bucket fill tool to precisely select areas you want to texture—or, even more powerful, areas you want to exclude (like the handle area of a microphone while leaving the top clear).

    Vibe Coding a Solution

    Vibe coding has become a popular way for novice programmers to fill in their knowledge gap with an AI assistant to create programming quickly. As Stefan explains, “Even though I can code reasonably well, building something like BumpMesh would have taken weeks of work at my own skill level…Vibe coding simply gives me the ability to go from an idea to a working custom solution in only a few hours.” He estimated it took only about a week of his time and $20 in subscription fees to Copilot.

    Privacy and Accessibility

    The core philosophy behind BumpMesh is simplicity and accessibility. It’s completely free, open-source, and best of all, runs locally in your web browser. There are no accounts to create, no license fees, and no tracking. Your files are processed right on your own computer, ensuring your designs stay yours.

    Still a Work in Progress

    While Hermann is realistic that the tool “isn’t perfect yet”, currently requiring multiple passes to apply multiple textures and having some limitations with extremely complex geometry, it’s an incredible start, especially considering it was developed in just a week. He’s already actively encouraging feedback and feature requests through platforms like Printables, Maker World, and GitHub.

    Fred the Frog with texture. Image courtesy of Denise Bertacchi.

  • EIT Manufacturing Liquidation Fracas Leaves 3D Printing Startup Out in the Cold

    EIT Manufacturing ASBL was a public-private partnership between the European Institute of Innovation and Technology (EIT) and a network of industrial and research partners. EIT is a European Union (EU) body, and European citizens can expect it to deliver on its promises. EIT Manufacturing, however, was a separate non-governmental body that helped disburse the EU’s money. By devolving responsibility and power to this supposedly faster and more efficient body, the EU gave up a teeny tiny sliver of its sovereignty to an external organization. We’re seeing this trend replicate itself worldwide. And yes, this may make government bodies more responsive, but it also carries risks.

    The EU’s anti-corruption body, OLAF, found irregularities and fraud at EIT Manufacturing on May 25. Subsequent to this, EIT stopped funding EIT Manufacturing, and the firm collapsed. Compared to the rampant and pervasive corruption in countries such as the United States, this is, of course, nothing, and proves that the system works. But at the same time, it suggests that public-private partnerships should be reexamined.

    Reportedly, over 200 startups are waiting for funding. This could be very nerve-wracking for them because it’s unclear if the money intended for them is gone or if there is just a delay due to EIT needing a new way to continue paying them. The truth is somewhere in the middle. In this case, some maintain that the entire paper chain needed to get grants is too time-consuming and complex, and the whole system needs an overhaul. There is also some worry about the fact that the first OLAF report stems from 2024; there was a reorganization, then new money was disbursed, only for OLAF to step in again much later.

    From LinkedIn and this startup blog, we can learn how one Maltese company, ELM, was affected.

    “ELM Fabrication Ltd, founded by engineers David Sciberras and Nicholas Borg Calleja, has developed a 2m x 2m x 6m model capable of 3D printing everything from boats to furniture out of recycled plastic…they secured an initial €217,000 in funding (70 per cent of the cost) from EIT Manufacturing (EITM) to bring the technology to market.”

    After green-lighting the project, the company never got the money. Worse still, they continued on the work using their own money and were promised reimbursement, which never materialized. Happily, the bootstrapped founders survived the ordeal,

    “However, we kept our operations lean. We didn’t give ourselves a salary or hire loads of people, although unfortunately we did lose people we were going to hire. It’s just good practice not to spend excessively before a product starts generating money.”

    It is, however, unclear when, if at all, the firm will receive its €217,000. ELM’s founders were indeed very frugal and careful, and this seems to have paid off for them. Thinking back, a few companies that I’ve advised would have been in serious trouble or gone under should government funding have dried up unexpectedly.

    David Sciberras gives an overview of what Invent 3D is up to at a joint chapter BNI Verdala Malta & BNI De Paule – Malta meeting. Image courtesy of David Sciberras via LinkedIn.

    On his LinkedIn, ELM Co-Founder David Sciberras explains that,

    “We always built to make money as quickly as possible. With ELM, the process was different as we’re building something new…. so we built things much more cautiously. Until the funds were in the account, we worked as if they weren’t there. Even after approval letters, promise of income, etc….until the money hit the account, we didn’t have funding. That helped us build a super lean setup, with zero waste. We built from Xjenza fund to TOSFA fund, putting in our own wages, late nights and expertise to make it happen. When we saw that EIT didn’t even send a signed grant agreement, alarm bells started ringing, so we pumped the breaks even harder on spending. This essentially slowed our path to market, by a year. Now that we opened up to a round of equity investment, we’re in a much happier place with our first investor on-board.”

    A few things here really stand out as excellent advice. “Until the funds were in the account, we worked as if they weren’t there,” feels like it should be standard practice anywhere. Promises are just that — promises. Also, I think many people wouldn’t have worried if the grant agreement hadn’t arrived. Many would have continued as normal, expecting some bureaucratic issue to resolve itself. Being as cautious and frugal as the ELM team seems to be is the new way of doing business. Slower, perhaps, but it gives you more control and helps move toward profitability more quickly.

    This collapse is significant because worldwide, more and more power is being given to public-private partnerships. Private firms are responsible for billions in government funding. The opportunities for corruption and lack of oversight are significant. We need to be ever-vigilant when applying for grants and, in a more uncertain world, even more frugal and careful.

  • 3D PRINT 2026: The Leading Additive Manufacturing Trade Show in France with 150+ Exhibitors

    From June 2 to 4, 2026, Lyon will host 3D PRINT, an event exclusively dedicated to additive manufacturing. As the only professional trade show in France fully focused on 3D printing, it has become a catalyst for innovation, business development, and strategic vision across the entire industry.

    By bringing together major industrial groups, SMEs, start-ups, and research centers, 3D PRINT is now recognized as a national leader, ranking among the three most influential additive manufacturing events in Europe. The show offers a unique platform to showcase technological advances and practical industrial applications of additive manufacturing across all key sectors.

    Bringing leaders and new players together

    This edition will gather industry leaders and new market entrants, including: 3D Consommables, 3D Newshape, 3D Prod, 3DPmolds, A.M.P.E.R.E., AddUp, Altair Consulting SA, AM Solutions, Ardiak, Atlix – Industrial Additive Manufacturing, Atome3D, Avenco, Axis, BigRep, Bureau Veritas, Institut Carnot Chimie Balard Cirimat, CoreTechnologie, Cylaos, Decip, EKZO BV, eMotion Tech, EOS SAS Electro Optical Systems, Eplus3D Tech GmbH, Erpro Group, Flow-3D AM, GMP ADDITIV, HP, Incus 3D, Initial, Jean Brel, Joke Technology, Kreos, La Nouvelle École, Linde AMT, Linde France, Multistation, NANOVAL GmbH, Novacad, Onshape by PTC, Philtec Système, Politechno, RBSystem, Renishaw, Replicad 3D, Reptis, SEIDO Systèmes, Simaform SA, SuNPe Prototype, Technologie Services, UpNano GmbH, Volumic 3D/La Ferme 3D.

    A tailored, free-to-access congress

    At the heart of the event, the 3D PRINT Congress offers over 50 conferences and workshops, all free and open to attendees. Visitors can create a tailored schedule based on their business priorities.

    French and international speakers are hand-picked for their expertise and invited to share exclusive insights and unique case studies. For international visitors, a live translation system ensures full accessibility and smooth participation across all sessions.

    The Creality booth at 3D PRINT 2025.

    An optimized, business-oriented visit

    To maximize the value of your visit, 3D PRINT 2026 offers:

    • Thematic visit routes, organized by France Additive, covering five strategic sectors: aerospace, automotive, medical, defense, and luxury. These visitor tours guide attendees to the most relevant solutions and connect them with key industry experts.
    • Business Connect, developed in partnership with France Additive, providing personalized support to project leaders in identifying the most suitable technological and industrial partners.

    Winning synergies

    With your 3D PRINT badge, you also gain access to France Innovation Plasturgie (FIP), the major event for the plastics, composites, and rubber sectors, which will welcome over 800 exhibitors.

    Attendees can also join two exclusive EPMA seminars focused on sectors where additive manufacturing plays a key strategic role: automotive and energy.

    How to Participate:

    Images courtesy of 3D PRINT Lyon

  • BigRep Launches ONE.5X 3D Printer, Announces New Massive Dimension Partnership at RAPID + TCT 2026

    As the whole world is starting to realize, the Hormuz supply chain fallout is only just beginning to filter into the global economy, and the rising cost of plastics should be a centerpiece of that story for some time. Under these conditions, large-format polymer additive manufacturing (AM) should get a boost, and pellet-extrusion systems, which are optimal for use with recycled materials, might benefit most of all.

    BigRep, then, the German-US original equipment manufacturer (OEM) of large-format polymer 3D printers, has perfectly timed two major announcements for RAPID + TCT 2026 in Boston: first, the company is releasing the BigRep ONE.5X, which the company is calling “a fully automated evolution” of the BigRep ONE.5 that it originally launched at Formnext 2024. Secondly, the OEM is providing further details on a previously announced partnership with Massive Dimension, the Vermont-based manufacturer of pellet head extruders.

    Through the partnership, the two companies will integrate the new Massive Dimension MDX extruder with the BigRep ONE platform, with the two companies aiming to make the combined solution available by the end of 2026.

    The connecting threads between the launch of the ONE.5X and the MDX integration with the ONE platform are ease-of-use and flexibility: the two offerings are designed to simplify the setup and maintenance experiences and to support a broad range of materials. BigRep leaned into that messaging with its presentation of the ONE.5 at Formnext 2025 — where the company also first announced the Massive Dimension partnership —and is making it even more prominent in its sales pitch for the ONE.5X.

    ONE.5 pellet system at a creative workshop. 

    Attendees of RAPID + TCT 2026 can learn more about the ONE.5X and the Massive Dimension MDX at Booth #2355.

    In a press release about BigRep’s launch of the ONE.5X and the integration of Massive Dimension’s MDX extruder with the BigRep ONE platform, Jeff Olson, President of BigRep America, said, “The ONE.5X represents everything we’ve learned from over a decade of industrial large-format 3D printing, as well as global customer feedback. All of that is distilled into a machine that delivers consistent results, regardless of an end-user’s experience level.”

    Meanwhile, Tyler McNaney, Massive Dimension’s founder and CTO, noted, “The MDX is not just an iteration. It’s a reset. We removed complexity and reduced weight to create a more capable and more adaptable extrusion system, built for where the market is going.”

    The best thing OEMs in the AM industry can do right now to help themselves is focus on making their machines as easy to use as possible. You don’t necessarily have to do this through the design of the machine itself; you can also focus on less direct solutions, such as creating standardized workforce development programs that could also serve as a source of revenue.

    ONE.5 at work. 

    But for companies where it’s a realistic option, tailoring the machine itself to maximize user-friendliness is only going to become an even stronger selling point in the years ahead, as the manufacturing sector becomes increasingly reliant on workers with no prior manufacturing experience. Aside from that, demand for automated systems is also likely to increase, as even inexperienced workers will be difficult to come by.

    Those aren’t exclusively technological considerations, of course, but also carry cost-of-ownership implications. Less experienced workers command lower salaries, and higher levels of automation limit the number of necessary hires altogether. This way of thinking isn’t meant to eliminate human thought from the process: in a country like the US, at this point, it’s likely the only approach that will ensure that the next generation of manufacturing is sufficiently staffed.

    Both of these moves also bode well for BigRep’s targeting of the tooling market for the defense sector, which the company signaled as a key priority last summer in its announcement of a sales partnership with Phillips Federal. Large-format tooling is a perfect use-case for pellet extrusion, and BigRep has very effectively synergized its market reach through both the Phillips Federal and the Massive Dimension partnerships.

    Images courtesy of BigRep

  • 3D Printing’s Chicken-and-Egg Problem: No Demand Without Scale, No Scale Without Demand

    There’s a simple problem at the center of the 3D printing industry, and it hasn’t really gone away.

    Companies say they will invest in additive manufacturing when there is steady demand. Customers say they will commit when it’s proven at scale. And so both sides wait.

    This is 3D printing’s version of the classic chicken-and-egg problem. And perhaps, it helps explain why, after years of innovation, the technology still isn’t widely used at a scale the way it was originally expected to.

    Visualization courtesy of 3DPrint.com.

    Waiting for Proof

    For many manufacturers, it’s not about whether 3D printing works. It clearly does. The challenge is making it reliable, cost-effective, and consistent at scale.

    If a company is going to switch part of its production to additive manufacturing, it needs to know that parts will meet the same standards every time, production can run without disruption, and costs will stay predictable.

    That kind of confidence usually comes from seeing the technology already being used at scale. But that’s exactly the problem.

    Waiting for Demand

    On the other side, 3D printing companies often need committed customers before they can scale up.

    Running machines at full capacity, investing in more equipment, and building out production workflows all depend on having enough demand to justify it.

    Without that demand, it’s hard to lower costs, improve efficiency, and prove long-term reliability. So suppliers wait as well.

    Where This Shows Up

    You can see this dynamic across the industry.

    In aerospace, for example, companies like Boeing and Airbus have adopted 3D printing, but mostly for specific parts rather than full production lines. The technology works, but scaling it across entire systems takes time, certification, and long-term proof.

    In defense, there is a strong interest in using 3D printing for spare parts and field production. But large-scale deployment still depends on qualification, repeatability, and trust in the process.

    Even in consumer products, where 3D printing offers clear advantages in customization, companies are often cautious. They may test the technology in limited runs before committing to larger volumes.

    But at the same time, there are signs that this is starting to change.

    Some of the largest manufacturers are beginning to move beyond isolated use cases. BMW, for instance, is integrating 3D printed parts across multiple vehicle brands, and not just for prototyping, but also for actual production components. Apple is also reportedly exploring 3D printing for aluminum components in future devices, which would mark a significant step toward scaling the technology for high-volume consumer products.

    These are still early moves, but they point in the same direction. As more companies begin to use 3D printing in real production environments, even in limited ways, it starts to build the confidence needed to expand further.

    In other words, the balance may slowly be shifting in favor of adoption.

    But the underlying pattern is still there: no scale without demand, and no demand without scale.

    BMW 3D printed robot gripper. Image courtesy of BMW.

    The Cost Loop

    Cost plays a big role in this cycle.

    3D printing becomes more competitive as production increases. More volume means better machine utilization, lower cost per part, and more refined workflows. But to reach that point, companies need enough demand in the first place. This creates a loop that is hard to break.

    There are signs that this is starting to shift. In some areas, demand is becoming strong enough to push past the hesitation. For example, large-format parts in both metals and polymers are gaining traction, reshoring efforts are driving interest in more flexible manufacturing, and industries like defense and energy are looking for faster, more adaptable production methods.

    At the same time, the technology itself is improving. Machines are becoming more reliable, materials are expanding, and post-processing is getting more automated. All of this helps reduce risk. And reducing risk is what breaks the cycle.

    Onward

    The industry is finding ways around the chicken-and-egg problem. In some cases, it starts with a single application. A company identifies one part where 3D printing clearly makes sense, proves it out, and then expands from there.

    In other cases, it comes from external pressure. Supply chain disruptions, geopolitical shifts, or the need for faster production can push companies to adopt additive manufacturing sooner than they otherwise would.

    What’s becoming clearer now is that this shift may already be underway.

    Recent data from Additive Manufacturing Research (AMR), also covered by analyst Scott Dunham in his latest webinar, looks at where real growth is actually happening in 3D printing. Instead of treating the industry as one single trend, it breaks the market down by segment, showing which areas, such as specific applications or technologies, are gaining traction. If you want to see how that shift is playing out in detail, the full webinar is still available to watch and offers a clear, data-driven look at where the industry is gaining traction.

    Scott Dunham during the AMS 2026 AM Applications Data presentation. Image courtesy of 3DPrint.com.

    That matters because it starts to break the cycle. When certain parts of the industry begin to grow, companies gain more confidence to invest in production. As production increases, costs can come down, and the process becomes more reliable, making it easier for new customers to adopt the technology.

    Once a few strong use cases are proven and the data starts to support them, the rest tends to follow.

    A Familiar Problem

    In many ways, this is not unique to 3D printing. Most new manufacturing technologies go through a similar phase. But in additive manufacturing, the cycle has lasted longer than many expected.

    The technology is ready in many ways. The machines work. The materials are there. The applications exist. What’s still catching up is the confidence to scale. And until that gap closes, the industry will keep running into the same question: What comes first, demand or scale?

  • Orano Federal Services & UNC Charlotte Show How AM Could Cut Costs in Nuclear Energy Resurgence

    Outside of the defense sector, few industries have been impacted by Russia’s ongoing occupation of Ukraine more than nuclear energy. The same appears to already be happening in response to the US-Israel attacks on Iran.

    Nations, including the US, that have seen a resurgent interest in nuclear energy since 2022 have learned that revitalizing a nuclear energy supply chain is anything but a short-term process. The long-term nature of nuclear energy buildup could work in favor of using additive manufacturing (AM) to aid in that buildup, and there has been notable growth in AM R&D for nuclear power applications over the last several years. A new case study from the University of North Carolina (UNC) Charlotte and nuclear cleanup specialist Orano Federal Services demonstrates how AM might be used not only to help make a US nuclear energy renaissance possible, but also to make such a scenario cheaper.

    The key to understanding how lies in spent nuclear fuel (SNF): these are the uranium oxide pellets used in fuel rods, which US nuclear facilities recycle at a rate of 2,000 metric tons a year. As the case study explains, the current recycling protocol in the US leaves individual operators in charge of their own disposal processes, but that’s expected to change over the next 10-15 years, the timeline that the Department of Energy (DOE) is targeting for the construction of a central repository for SNF. This creates demand for the production of the hardware required for transporting SNF, most notably transportation casks.

    These are giant structures, with typical casks used for truck transport weighing 50,000 pounds and those used for rail transport weighing as much as 250,000 pounds (in both cases, the weight includes the fuel). The Orano and UNC Charlotte case study involves using AM to produce impact limiters for casks: circular components that sit at both ends of a cask, designed to protect its contents in the event of an accident.

    For the case study, researchers tested both fused filament fabrication (FFF) and powder bed fusion (PBF) methods, substituting stainless steel for the conventionally-used materials, which are most often redwood or balsa-wood, or aluminum. Using both simulations and real-world compression testing, the Orano and UNC Charlotte team determined that a 5 percent gyroid infill design, for FFF as well as PBF, “produce[d] acceptable results for drop events”. Assuming a cost of up to $1 million per impact limiter when produced conventionally and 2 impact limiters per cask, the researchers found that using AM could result in up to $1 million in savings per cask with FFF and up to $1.7 million with PBF.

    Results of compression testing: honeycomb design (top row) vs gyroid design (bottom row).

    Of course, the caveat, as usual with AM components, is that the lack of existing relevant standards stands in the way of pivoting to AM at scale:

    As the case study notes in its conclusion, “However, the lack of codes and standards to support the use and verify the efficacy of AM components makes the proposed new impact limiter design an exercise in need of justification, likely beyond single component testing and numerical modeling of the composite design and most likely in need of actual drop testing data. Therefore, although this work shows the promise of AM, the path forward is focused on the development of codes and standards for AM components, which will require test data to complete.”

    AM PLA plastic scaled replica of an impact limiter (1/12 scale) with 36 bricks (red, blue, and gold) and stainless steel cladding (green) and gyroid infill pattern in foreground (pink).

    On the other hand, the qualification process should be made easier precisely because the R&D is related to a DOE objective. As Vanesa Listek described in her excellent article on the many ways 3D printing contributed to the Artemis II launch, AM tends to prove most viable when its use is supported by the combination of public and private funding to solve a complex of technological problems over a lengthy timeframe.

    Nuclear energy can be thought of as a space program that doesn’t leave orbit. It’s one of those quintessential technological arenas that has never existed, and probably can’t/shouldn’t exist, without heavy government involvement. That’s exactly the sort of context that calls for a publicly funded qualification accelerator program.

    That is the case, especially given the value inherent in recycling SNF. In addition to its potential viability as a future fuel source, the material can also be used for a growing number of applications, including medical treatment. That provides an additional incentive for the government to expedite the process, enabling the use of new manufacturing techniques for SNF transportation.

    Finally, as the entire AM industry has benefited from the knock-on effects of federal funding for accelerated standardization in the defense sector, the entire industry would benefit from a concentrated effort to expand AM use in nuclear energy. Given all the government money already spent on R&D for nuclear submarines, there’s even greater potential to combine those two goals.

    Images courtesy of Radwaste Solutions/ American Nuclear Society

  • 3D Printing News Briefs, April 8, 2026: LiDAR Scanning, Vapor Smoothing, FDM Optimization, & More

    We’ll kick off today’s 3D Printing News Briefs with some 3D scanning news from Artec 3D, and then move on to new America Makes Project Calls. Then, Raise3D and AMT are partnering for post-processing, and amsight launched a new website. Finally, we’ll end with a new tool that offers AI-generated optimization reports for FDM 3D printers.

    Artec 3D Debuts SLAM-Powered LiDAR Scanner at Manufacturing World Nagoya

    Artec Jet

    At Manufacturing World Nagoya, which kicked off in Japan today, Artec 3D is launching its newest scanner, the Artec Jet: a powerful, survey-grade, SLAM-based LiDAR system for autonomous and precise 3D data capture at scale. The company says this fast, versatile scanner pairs high-density LiDAR sensors with SLAM positioning algorithms to capture large areas with an accuracy of ±10 mm indoors and underground, including in GPS-denied environments that traditional 3D mapping technologies can’t handle. Weighing in at just 1.57 kg, it’s said to offer a 360° x 290° field of view, a companion app for real-time feedback, IP65 dust and water protection, and autonomous flight control. In fact, one of the best-sounding features is the Artec Jet’s ability to scan fully autonomously, without human input, onboard a drone—independently mapping its own flight paths, maintaining stable positioning, and avoiding very small obstacles. The scanner is deployable by hand, vehicle, and drone, and used with Artec 3D’s new Artec Twins software, the company’s ecosystem can capture accurate digital twins on any scale.

    “With Artec Jet, we’re entering an exciting new chapter. Our mission has always been to make 3D scanning as fast, accurate, and intuitive as possible. Artec Jet expands this approach into larger environments, empowering our customers to capture infrastructure with the same level of confidence and ease,” said Art Yukhin, President and CEO of Artec 3D. “This incredibly versatile device brings unprecedented speed, precision, and autonomy to reality capture at scale.”

    Come hear more about the Artec Jet at the Data Design Booth 15-103, Hall 1. 3DPrint.com is a proud Media Partner of Manufacturing World Nagoya.

    America Makes and NCDMM Announces Two Project Calls

    Last week, America Makes and the National Center for Defense Manufacturing and Machining (NCDMM) launched their latest two Project Calls. Both are funded by the Office of the Under Secretary of Defense, Manufacturing Technology Office (OSD ManTech), and are worth a combined $14.5 million in funding. The first is the $9 million Delta Qual 2.0, which is focused on addressing key AM qualification challenges across the Defense Industrial Base to support Department of War (DoW) objectives for advanced manufacturing solutions. This will happen by streamlining the requirements for testing, increasing processing parameters flexibility, and making machine installation standards stronger. There will be three topic areas for Delta Qual 2.0, and participants are expected to deliver outcomes that can provide mutual value to the DoW and Organic Industrial Base (OIB), as well as “actionable insights” that can decrease both industrial and technical risk.

    The second Project Call, worth $5.5 million in funding and consisting of two phases, is Generation Of Technical-data for High-strength Aluminum Alloy Material, or GOTHAAM. The focus is developing material allowables, over three classes of laser powder bed fusion (LPBF), for a high-strength 7075-T73-equivalent aluminum alloy. By coming up with an aerospace-grade, corrosion-resistant alloy with both commercial and defense applications, this will enable scalable production of all sizes of 3D printers, and could generate a strong ROI for OEMs and the OIB as the material transitions into qualified production. Main priorities include characterizing the alloy’s environmental durability, stress-corrosion cracking behavior, and fatigue-crack growth performance, to make sure the aluminum alloy is able to support high-strength, long-life structural applications. Proposals for both Delta Qual 2.0 and GOTHAAM are due by 5 pm ET on June 2, 2026.

    Raise3D & AMT Bringing Post-Processing to RMS220 Customers in Europe

    Raise3D AMT PostPro SFX Starter Bundle

    3D printer manufacturer Raise3D announced that it’s partnering with Additive Manufacturing Technologies (AMT) to enable production-ready SLS workflows. As part of their agreement, Raise3D will offer AMT’s vapor smoothing solutions, including the current SFX and upcoming SF2X systems, to its clients in Europe. This will bring professional post-processing abilities to Raise3D’s RMS220 SLS 3D printer, and allow customers to efficiently print functional end-use parts with high-quality surface finishes. Raise3D’s AMT PostPro SFX Starter Bundle offers pre-configured AMT systems that are compatible with Raise3D powder materials. The €17,999.00 bundle includes a one-year warranty, one PostPro SFX—providing improved capacity for processing large builds—with PostPro Pure solvent cartridges, one storage stand, three processing racks, one cartridge of FA5802 finishing agent, and two air filters.

    “Our partnership with Additive Manufacturing Technologies (AMT) completes our additive manufacturing workflow with advanced post-processing capabilities. AMT’s powerful yet user-friendly systems deliver industry-leading surface finishing and perfectly complement the large build volume of our RMS220,” said Fernando Hernandez, SLS Product Marketing Manager – Europe at Raise3D.

    “This collaboration represents another step toward our goal of delivering a complete, end-to-end additive manufacturing solution.”

    As Quality Management for AM Matures, amsight Launches New Website

    As its production-level quality management system (QMS) continues to mature, Fraunhofer spin-out amsight has launched a new website that reflects its evolution as a company. amsight is focused on data-driven quality management for additive, and developed production-level QM software for AM. Instead of presenting its offering as a generic platform, the new site structures content by use case, including traceable production data and automated documentation; proving part conformity with standardized, audit-ready reports; and process/machine qualification supported by SPC and IQ/OQ/PQ evidence. The homepage helps guide visitors to solutions, showcasing real-world use cases and quantified results, and an integrated ROI calculator helps them estimate the impact of switching to amsight’s QM software. The site’s Resources section was also revamped, and separates lengthy whitepapers and guides from shorter insights.

    “Our customers aren’t looking for another dashboard. They need a reliable way to link powder, builds, post-processing, and inspection into one quality backbone that connects to their machines, MES, and ERP systems. The new website is our way of showing, in concrete terms, how amsight fills that gap,” explained amsight CEO and Co-Founder Tim Wischeropp.

    “With this site, we wanted to make two things obvious. First, that amsight is an AM-specific quality management software, not a replacement for ERP or MES. Second, that data-driven quality isn’t a future vision, it’s already working today in space, aerospace, and semiconductor supply chains.”

    BambuTune’s AI-Generated FDM Printer Optimization Reports

    Screenshot of BambuTune sample report

    On its website, BambuTune, an autonomous AI company powered by NanoCorp, claims to offer “AI-powered print optimization for every FDM 3D printer.” This tool generates personalized optimization reports for a variety of FDM printer brands, from consumer to professional. The website says BambuTune supports over 70 printers across more than 16 brands, including Elegoo, Creality, Bambu Lab, Snapmaker, Prusa, Flashforge, Qidi Tech, AnkerMake, Longer, and more. It sounds simple enough: users select their printer model, filament type, and settings, and describe the issue they’re having. Then, the AI-driven tool compares your settings to community-validated recommendations, and spits out a detailed report that includes specific recommendations, covering things like retraction tuning, temperature optimization, speed settings, flow rate precision, and more. You can see a sample report for a Bambu P1S here.

    “Our AI optimization engine draws on community-validated settings and expert knowledge across the entire FDM ecosystem — from budget Ender-3s to premium Bambu Lab X1Cs. We know what works for every printer,” the website states.

    It costs $4.99 for one report, or an Early Bird rate of $14.99 a month for unlimited reports. BambuTune also orders a “100% Money-Back Guarantee,” no questions asked, “if our tips don’t save you filament.”

  • When Creativity Has Meaning: How Young Makers Create Real Impact

    Some children discover the world early. Others discover how to reshape it.

    Across communities, a growing number of young creators are using technology not just to develop skills or earn money, but also to support families, care for friends, and address real emotional needs. This shift from making for profit to making for meaning is at the center of When Young Minds Create, a youth-focused maker program supported by Creality.

    Positioned as a community‑centric youth movement rather than a traditional education or business program, the initiative encourages children to treat creativity as a form of responsibility, empathy, and social contribution. Technology is a tool, and human impact is the goal.

    Within weeks of launch, the program attracted nearly 200 young participants worldwide. While their projects varied widely, a common pattern quickly emerged: most were designed with specific people and needs in mind. Through in-depth conversations with more than 40 young makers, the program revealed how creativity is shaping people’s real lives.

    Many participants have already taken their work beyond their homes, setting up booths at local markets, sharing creations with classmates, and offering customized designs within their communities. In these settings, technology becomes a means of connection and expression rather than an end in itself.

    Ealan and Taleah: Learning Responsibility Through Making

    Ealan and Taleah with their Autistic Prints.

    When Ealan and his sister Taleah first started selling their 3D printed items, their goal was simple and familiar to many kids their age: save enough money for a new game console.

    That plan changed quickly. After their father unexpectedly lost his job, the siblings made a quiet but meaningful decision. Instead of saving money for themselves, they chose to use their earnings to help support their family.

    What began as a hobby suddenly carried a deeper purpose.

    The two siblings soon discovered how naturally their strengths complemented each other. Ealan enjoys designing and experimenting with new models, while Taleah thrives when interacting with customers and explaining their creations.

    Running their booth also helped Ealan overcome challenges beyond design. Living with autism, ADHD, and a rare skin condition that makes him prone to overheating, he often finds new environments and social interactions difficult. But when visitors ask about the designs, he enjoys explaining how the ideas came together, and those conversations are gradually building his confidence.

    Taleah continues to design customized pieces, often creating small gifts for friends and classmates. Her encouragement has helped her brother grow more comfortable sharing his ideas.

    Together, their experience shows how creativity can become more than a hobby. It can become a way for young people to support the people who matter most to them.

    HUGO: Engineering Solutions on the Track

    Hugo is participating in the Kart Race.

    A karting track is never only about speed. For Hugo, a young karting racer who spends much of his time around the track and paddock, it is also a place full of problems waiting to be solved.

    While watching mechanics and racers prepare their karts, he began noticing small inefficiencies that others often overlooked — tools that were difficult to reach, tangled cables, and components that wore down quickly.

    To most people, these details were simply part of racing life. To Hugo, they were opportunities for better design.

    Using 3D printing, Hugo started transforming his ideas into practical solutions. By designing and producing parts such as invented brake covers and battery-box components for wet conditions, he has been able to test improvements directly on the track.

    The ability to prototype quickly has allowed him to refine his designs and share them with other racers and mechanics, turning simple observations into usable engineering solutions.

    Dahlia: Creating for Calm, Care, and Emotional Well-Being

    Dahlia with her Doodles and Daydreams Studio.

    Dahlia’s project began with someone very close to her heart. Her best friend, Everly, had spent more than five months in a children’s hospital nearly five hours away from home.

    Wanting to help in some way, Dahlia began designing small tactile objects to comfort children experiencing anxiety or stress. Her creations include finger fidgets, spiral puzzles, calming stones, and simple classroom tools designed to support emotional regulation.

    Her empathy comes from personal experience: her brother also faces sensory challenges, and she has seen firsthand how such tools can support focus and emotional well-being.

    Through these designs, Dahlia aims to create small but meaningful tools that children can turn to whenever they need comfort, focus, or reassurance, demonstrating how creativity can translate empathy into tangible support.

    Technology as a Means, Not the Message

    Within When Young Minds Create, success is not measured by output volume or technical complexity. Instead, attention is placed on confidence gained, empathy expressed, and responsibility assumed.

    As more stories emerge, the program reveals a simple truth: when creativity carries purpose, its impact extends far beyond what is printed.

    Images courtesy of Creality