Additive Manufacturing Media

12/12/2025

PIC OF THE WEEK 📸 This week’s Pic depicts a swap in material and process that is now saving the U.S. Coast Guard an estimated $200K per cutter.

This drain cover was previously sourced as a cast bronze part, which suffered corrosion and required regular replacement.

Switching to 3D printed Ultem circumvents corrosion and reduces the cost of the part, not to mention dramatically simplifying the process to replace a drain cover when needed.

Switching from cast bronze to 3D printed polymer reduces the cost and difficulty of replacing an on-ship drain, saving an estimated $200K per Coast Guard cutter.

stats:
🧵Material: Ultem
➡️Process: Fused filament fabrication (FFF)
💵Part cost: $60
⏱️Installation time: 3 hours (down from 3 days)

MORE: https://www.additivemanufacturing.media/articles/pic-of-the-week-coast-guard-counters-corrosion-by-swapping-metal-for-3d-printed-polymer?utm_source=Social&utm_medium=Facebook

12/11/2025

CarbonForm’s 3DFit technology combines robotic, continuous fiber 3D printing and winding to produce small, high-strength, complex parts — like drone frames — in as little as 10 minutes.

As the market demand for drones grows, there is a need for technologies able to produce repeatable, scalable, high-performance — and often complex — drone components including their frames. Delaware startup CarbonForm is targeting small, high-performance, complex parts like drone frames with its patented 3DFiT continuous composites technology.

The automated 3DFiT — short for 3D Fiber Tethering — process involves depositing a continuous fiber thermoset material onto a 3D scaffold. Enabled by a robot-mounted print head, the strategy makes effective use of both topology optimized design and the inherent properties of the continuous fiber composite material.

“This process gives us 3D spatial placement to make actual 3D monolithic structures that are high strength ... in minutes.”

For demonstration, CarbonForm recreated and optimized a jet engine bracket, achieving a weight savings of about 93% and tensile strength up to 45 kN versus 36 kN for the original titanium design.

Entering the market with drone frames, prototypes show improved flight endurance and durability, manufactured in about 10 minutes per part, with no joints for enhanced strength.

A portable, manual version enables in-field fabrication of glass fiber composite drones ready to fly in less than 30 minutes.

How might topology-optimized composites transform your high-stress applications? What challenges do you face in producing complex, lightweight parts?

Read the full article for more insights: [link to article] https://www.additivemanufacturing.media/articles/3d-fiber-tethering-for-rapid-fabrication-of-continuous-fiber-composites--2

12/10/2025

"More than anything, Formnext 2025 felt like a gathering of technology suppliers and users that have begun to work together in earnest to solve the challenges that have plagued AM for so long," says AM's Stephanie Hendrixson of this year's Formnext - Where ideas take shape.

The sense of collaboration was coupled with a weightier, more industrial feel to the trade show. The takeaway? Additive manufacturing has arrived, it is making end-use parts, and it is doing so for some of the most critical and regulated industries out there.

6 TRENDS FROM FORMNEXT 2025:

Advances in LPBF, possibilities for ceramics and encouraging news about supplier consolidation were among the hot topics at this year’s show.

12/05/2025

The U.S. Navy’s recent Fleet experimentation exercise showcased the power of field-deployable 3D printing and on-demand production, facilitated by Stratasys Direct. This innovative approach to manufacturing is a game-changer for military operations. Distributed manufacturing not only enhances resilience in supply chains but also significantly boosts military readiness by enabling rapid, on-site production of critical components.

Imagine the strategic advantage of producing parts exactly when and where they’re needed, minimizing delays and reducing dependency on distant suppliers. This exercise proves that additive manufacturing can transform logistical challenges into operational strengths, ensuring that our forces are always prepared.

How could distributed manufacturing impact your industry’s supply chain resilience? Are there opportunities to integrate on-demand production into your operations to address urgent needs or reduce downtime? Let’s discuss the potential of these technologies to redefine efficiency and readiness in high-stakes environments.

For a deeper dive into the Navy’s groundbreaking approach and the implications for distributed manufacturing, read the full article on our website. Link in the comments. https://www.additivemanufacturing.media/articles/in-the-news-distributed-manufacturing-8000-miles-apart

12/04/2025

The U.S. Coast Guard has achieved a groundbreaking milestone in metal additive manufacturing with the installation of 3D printed covers on the CGC Forward earlier this year. These components, critical seal housings for the cutter’s fin stabilization system, represent a crucial step in reinforcing the supply chain for metal replacement parts. Facing logistics challenges and the unavailability of traditionally machined parts, the Coast Guard, in collaboration with the Navy Center of Excellence, turned to additive manufacturing to produce these housings using laser powder bed fusion. This approach not only saved time and cost but also upgraded the material to corrosion-resistant 316 steel.

As Commander Andrew Armstrong notes, “When you look at the part, it does not scream additive... But when you look at the amount of time to machine all that material out and the cost, it starts to make a lot more sense.” Installed in January 2025, these parts have been in service for over 11 months with no issues, potentially paving the way for less aggressive replacement schedules and long-term savings.

How do you see additive manufacturing reshaping supply chain challenges in your industry? What potential do you see for 3D printing critical components in your operations? Dive into the full story on our website to explore how this innovation is transforming military asset maintenance. Share your thoughts or experiences in the comments below. https://www.additivemanufacturing.media/articles/coast-guard-installs-first-critical-3d-printed-metal-parts-fin-seal-housing-cover

12/02/2025

Streamline 3D is revolutionizing additive manufacturing with a unique approach to custom finishes, prioritizing both aesthetics and functionality to drive customer satisfaction. Based in Fresno, California, the company has partnered with Keyland Polymer to introduce UV-curable powder coatings, offering vibrant, scalable color options for 3D printed parts—a longstanding industry challenge. This technology melts at lower temperatures, cures instantly under UV light, and slashes processing times, enabling high-quality results in just 8 minutes compared to weeks with traditional methods.

Beyond color, Streamline 3D provides a range of finishes, from shot peening for scratch resistance to v***r smoothing for moisture protection, catering to industries like automotive, medical devices, and electronics. As founder Cody Laursen notes, aesthetics often determine a customer’s first impression, making finishing as critical as the printing process itself. This dual focus on form and function is expanding the horizons of what’s possible in AM.

How do you see advanced finishing solutions impacting the adoption of 3D printing in your industry? What challenges have you faced with achieving consistent aesthetics in printed parts? Dive deeper into Streamline 3D’s innovative approach and their transformative partnership with Keyland Polymer by reading the full article on our website. Let’s discuss your thoughts in the comments below. https://www.additivemanufacturing.media/articles/finishing-additively-manufactured-parts-with-uv-powder-coating-2

12/01/2025

Robotic arms in 3D printing are transforming the industry, and Ulendo is at the forefront with a groundbreaking tool to address a critical challenge: vibration. Their innovative solution compensates for vibration in robotic arms, ensuring precision and quality in additive manufacturing. Perhaps most compelling is the potential benefit this offers— the opportunity to utilize smaller, lower-cost robots without compromising on print quality.

This advancement could redefine cost structures and accessibility for manufacturers, allowing more companies to adopt advanced 3D printing technologies. As the industry continues to evolve, tools like Ulendo’s are paving the way for greater efficiency and scalability in production processes.

How do you see vibration compensation technology impacting the future of robotic 3D printing? Are there other barriers to adopting smaller, cost-effective robots in your operations? Share your thoughts in the comments below, and dive deeper into this innovation by reading the full article on our website. Let’s discuss how such advancements can shape manufacturing strategies for managers and engineers alike. https://www.additivemanufacturing.media/articles/vibration-compensation-for-robot-based-3d-printing

11/28/2025

Mantle, the developer of a groundbreaking hybrid metal additive technology for injection mold tooling, has been acquired by Angstrom, a prominent automotive and industrial supplier. This acquisition signals a potential shift in the additive manufacturing landscape, particularly for tooling applications. As highlighted in our latest article, Angstrom seems dedicated to advancing adoption through tooling services, yet it remains uncertain whether selling machines will be part of their strategy moving forward.

This development raises critical questions for managers and engineers in the manufacturing sector. How will Angstrom’s focus on services impact the accessibility of Mantle’s innovative technology? Could this acquisition accelerate the integration of additive solutions in traditional industries like automotive?

For a deeper dive into the implications of this acquisition and what it means for the future of metal additive manufacturing, read the full article on our website. We explore the potential strategies and the broader impact on tooling innovation.

What are your thoughts on this acquisition? Do you see Angstrom’s service-oriented approach as a step forward for wider adoption of hybrid additive technologies? Share your insights in the comments below and let’s discuss the future of manufacturing. https://www.additivemanufacturing.media/articles/in-the-news-angstrom-group-acquires-mantle-

11/25/2025

Advances in laser powder bed fusion, possibilities for ceramics, and encouraging news about supplier consolidation were among the hot topics at Formnext 2025. Held in Frankfurt, Germany, this year’s additive manufacturing trade show drew over 38,000 attendees and featured 800+ exhibits across 50,000 square meters. From new LPBF efficiencies with machines like the EOS M4 Onyx to the commercialization of 3D printed ceramics for end-use parts, the event showcased AM’s growing maturity. Supplier consolidation also stood out, with acquisitions like Airtech’s expansion into filament and Siemens’ integration of Altair enhancing user value through streamlined workflows.

Notably, the industrial focus was clear—AM is now producing critical components for defense, medical, and semiconductor industries. Trends like total cost of ownership reduction and software innovations further signal the technology’s readiness for broader adoption. Formnext 2025 felt like a turning point, with suppliers and users collaborating to tackle long-standing challenges.

What trend from Formnext 2025 are you most excited about—ceramics, LPBF advancements, or consolidation benefits? Share your thoughts below, and dive deeper into these insights by reading the full article on our website. Let’s discuss how these developments could impact your industry. https://www.additivemanufacturing.media/articles/formnext-2025-balances-innovation-with-industrialization-6-trends

11/24/2025

Electron beam melting (EBM) is revolutionizing the way we approach 3D printing of metal parts. As a powder-based process, EBM uses electrons as the energy source to fuse metal powder, creating highly precise and complex components. This technology offers unique advantages, including the ability to produce parts with exceptional material properties and reduced internal stresses, making it a game-changer for industries like aerospace and medical manufacturing.

In our latest introductory video, we dive into the intricacies of how EBM works and explore its key benefits for engineers and managers looking to optimize production processes. From enhanced design freedom to improved part performance, this method is paving the way for innovation in metal additive manufacturing.

Curious about how EBM can transform your manufacturing approach? What challenges do you face in producing complex metal parts that this technology might address? Share your thoughts in the comments below, and click the link to watch the full video and read more about this cutting-edge process on our website. Let's discuss how EBM could fit into your next project. https://www.additivemanufacturing.media/articles/get-familiar-with-electron-beam-melting-(ebm)

11/21/2025

It’s inevitable — we came across a Cool Part at .

Do you see it?

11/21/2025

The U.S. Navy’s Maritime Industrial Base (MIB) Program, alongside General Dynamics Electric Boat and Lincoln Electric, is making significant strides in naval manufacturing. Their latest investment focuses on integrating additive parts into nuclear-powered submarines, a move set to revolutionize production timelines. As highlighted in our recent article, 3D printing is poised to play a pivotal role in completing three submarines by 2028.

This strategic adoption of additive manufacturing not only addresses supply chain challenges but also accelerates innovation in a critical defense sector. By leveraging advanced technologies, the program aims to enhance efficiency and maintain the Navy’s operational readiness.

How do you see additive manufacturing shaping the future of defense industries? Are there other sectors where 3D printing could drive similar transformative change? Share your thoughts in the comments below.

For a deeper dive into how these partnerships are redefining naval engineering and the specific technologies at play, read the full article on our website. Let’s discuss the implications of this technological shift for the industry.

[Link to full article] https://www.additivemanufacturing.media/articles/in-the-news-integrating-am-into-nuclear-sub-construction