Additive Manufacturing Media

Additive Manufacturing Media We are the media brand devoted to industrial applications of 3D printing technology. Instead, we speak to a manufacturing audience.

Additive Manufacturing is devoted to industrial applications of 3D printing and digital layering technology to make functional parts. We don’t cover 3D printing as it relates to making design models, movie props, sculpture or swimwear (sorry). We are exploring the use of additive manufacturing to make tooling, molds and functional prototypes, along with the ultimate aim of manufacturers: end-use p

roduction parts. We report on the promise of additive manufacturing in these applications. We also report on the pitfalls. Staff members write about successes with additive manufacturing and the hard roads that led to those successes.

Depowdering is often overlooked as a pain point in additive manufacturing production — but it may need to be addressed a...
06/02/2026

Depowdering is often overlooked as a pain point in additive manufacturing production — but it may need to be addressed as early as the design phase.

Solukon debuted a special configuration of its SFM-AT350-E automated depowdering system at RAPID + TCT 2026, specifically reconfigured to accommodate the EOS M4 Onyx 3D printer and enabling the depowdering of compact metal parts.

Key capabilities of this configuration include:

- Two-axis swivel and flexible rotary table for precise motion control
- High, self-regulating ultrasonic vibration via piezoelectric excitation for gentle, thorough cleaning
- Manual depowdering through sealed glove ports using compressed air or inert gas
- Optional integration with SPR-Pathfinder software, which uses a part's CAD file and digital twin to determine optimal powder removal sequences for complex interior structures

The system is designed for parts with a Z-height below 250 mm and weighing up to 100 kg — suited for delicate applications such as medical components.

"Our most important challenge is to grow with the printers," notes Marina Haugg of Solukon — a directive that extends across part sizes, from compact geometries to assemblies exceeding two tons.

Full coverage linked below. https://www.additivemanufacturing.media/articles/ultrasonic-vibration-enables-automated-depowdering-of-compact-parts

Designing a functional metal multi-tool through additive manufacturing is harder than it looks.At RAPID + TCT 2026, a te...
05/29/2026

Designing a functional metal multi-tool through additive manufacturing is harder than it looks.

At RAPID + TCT 2026, a team of students from the University of Texas at El Paso — competing as Borderland Steel — took first place in the third annual AM in Steel competition, organized by America Makes. Their entry: a 3D printed stainless steel 316L multi-tool produced using laser powder bed fusion (LPBF) technology.

The process was far from linear. The team navigated:

- A failed first print caused by support structure issues
- A design that expanded to 20 parts before being consolidated to five through feature integration and lattice structures
- Postprocessing challenges requiring wire EDM, sandblasting, drills, pliers, and a lathe

What the experience demonstrated is the practical value of metal AM's design flexibility — the ability to iterate orientations, geometries, and configurations without disrupting final production.

The finished multi-tool performed across more than ten functionalities, evaluated live before a panel of judges.

Full details on the design, fabrication process, and lessons learned are available to read now. https://www.additivemanufacturing.media/articles/utep-students-win-2026-am-in-steel-competition-with-3d-printed-multi-tool-

U.S.-based binder jetting contract manufacturer Azoth 3D has scaled metal additive manufacturing for end-use components ...
05/26/2026

U.S.-based binder jetting contract manufacturer Azoth 3D has scaled metal additive manufacturing for end-use components through partnerships with Elnik Systems and DSH Technologies.

The company identified sintering as the central challenge when producing corrosion-resistant parts for automotive, medical and defense applications. Meeting strict purity and qualification requirements across multiple alloys required precise equipment and process expertise.

Azoth addressed these demands by working with Elnik for batch furnaces with all-metal retorts and atmospheric control, and with DSH for debinding and sintering development. These collaborations supported consistent results and reduced operational risk.

Read the full article to examine how these relationships enabled production-scale binder jetting. https://www.additivemanufacturing.media/articles/strong-partnerships-mean-success-for-binder-jetting-manufacturer

Additive manufacturing is expanding beyond in-the-field repair to serve as an alternative or supplemental process in the...
05/21/2026

Additive manufacturing is expanding beyond in-the-field repair to serve as an alternative or supplemental process in the defense supply chain.

Conversations with exhibitors and attendees at RAPID 2026 identified specific niches where the technology is now a critical capability. These include armored vehicle components made from refractory materials, hypersonic engine parts produced with niobium and Inconel, and drone components that benefit from rapid development cycles and lightweighting through design for additive manufacturing.

Additional applications cover on-demand repair and replacement parts that reduce complexity and downtime, expeditionary manufacturing systems for deployment in depots and aboard ships, and suppressors that take advantage of geometric complexity for efficient batch production.

The full article examines these use cases in greater detail. https://www.additivemanufacturing.media/articles/what-roles-is-am-playing-in-the-defense-supply-chain-rapid-2026-takeaways

Additive manufacturing enables the precise redesign of assistive medical devices that demand both structural performance...
05/19/2026

Additive manufacturing enables the precise redesign of assistive medical devices that demand both structural performance and user comfort.

Three M Tool and Machine has applied its in-house capabilities to rethink mouthsticks for individuals with restricted hand or arm mobility. The devices must remain stiff and lightweight while supporting accurate interaction with touchscreens during everyday use.

- Carbon fiber tubes are used for the adaptor that connects to the stylus tip.
- Markforged Onyx and a polycarbonate blend have been evaluated for the mouthpiece to balance rigidity and weight.

Recent work has extended and strengthened the mouthpiece tips. The company is also collaborating with an external design service to refine material selection and overall configuration. Several models are now in active use. https://www.additivemanufacturing.media/articles/post-cure-3d-printed-plastic-composite-mouthstick-designs-assists-limited-mobility-users-2

Large-format additive manufacturing (LFAM) is enabling faster, stronger production of marine structures.We're covering f...
05/12/2026

Large-format additive manufacturing (LFAM) is enabling faster, stronger production of marine structures.

We're covering five stories detailing LFAM’s growing role in the marine sector:

- Newsfender EU launches 3D printed, sustainable boat fenders using industrial large-format 3D printers from BigRep for on-demand, customizable production of protective hardware made from recyclable TPU material.

- Nugae leverages LFAM technologies to 3D print a structural component for a 43-foot catamaran, made of 70% recycled material.

- Budapest-based Rapid Prototyping integrates LFAM into production processes for manufacturing plugs used to build fiberglass molds for boat hulls.

- Caracol utilizes its Heron 300 system to 3D print a 4,200 × 400 × 400 millimeter, 40 kilogram side air intake grille for Pershing Yachts’ GTX116 sports utility yacht.

- A collaboration between V2 Group and Caracol AM produces a full-sized, functional catamaran 3D printed in under six days.

Read more about these applications. https://www.additivemanufacturing.media/articles/5-examples-of-lfam-in-the-marine-sector

OEM and social enterprise re:3D develops large-format 3D printers in the U.S. with a focus on sustainability, upgradabil...
05/07/2026

OEM and social enterprise re:3D develops large-format 3D printers in the U.S. with a focus on sustainability, upgradability and enabling economic independence anywhere.

The company addresses manufacturing challenges like equipment obsolescence and material waste by designing open-source Gigabot machines that offer perpetual upgrade paths, ensuring no printer becomes a paperweight.

As a social enterprise, re:3D empowers users through initiatives such as the GigaPrize, donating machines to community innovators, and Gigalab systems that convert plastic waste into valuable products.

Local sourcing and U.S.-based production support applications from defense to space, including compact printers for recycling in microgravity.

Read the full profile to explore how these choices foster local problem-solving. https://www.additivemanufacturing.media/articles/making-(and-re-making)-with-large-format-additive-manufacturing

K-Rain shaved 20% off the cycle time for a high-volume product with a new conformally cooled insert printed by Zero Tole...
05/05/2026

K-Rain shaved 20% off the cycle time for a high-volume product with a new conformally cooled insert printed by Zero Tolerance using Xact metal technology.

Unhappy with the cycle times and part aesthetics achieved with existing sprinkler-head tooling, K-Rain Manufacturing sought a conformally cooled alternative after conventional methods, including stainless steel water lines and thermal pins, provided insufficient improvements.

Partnering with Zero Tolerance, Xact Metal, and Reaction Plastics Solutions, the team applied direct metal laser sintering to print inserts in Uddeholm Corrax stainless tool steel. Post-printing heat treatment and machining achieved 50 HRC hardness and an A2 surface finish.

The inserts reduced cycle time from 52 to 41 seconds, with eight seconds attributed to the conformal cooling circuit, and eliminated sink from the part’s surface. Moldex3D simulations confirmed combined fill, pack/hold, and cooling time dropped from 26.39 to 24.05 seconds, with maximum temperature reduced from 128°F to 96°F.

Read the full article for details on this tooling optimization. https://www.additivemanufacturing.media/articles/sprinkler-head-mold-feels-more-flow-with-conformal-cooling-2

Nuclear fusion could soon generate power on Earth, but it requires robust components to manage heat and particles safely...
04/30/2026

Nuclear fusion could soon generate power on Earth, but it requires robust components to manage heat and particles safely.

Researchers at Oak Ridge National Laboratory are exploring fusion technology alongside electron beam melting (EBM) to produce essential parts, such as divertor tiles made from tungsten.

These tiles direct particles and heat flux away from the reaction in magnetic confinement devices, ensuring stability. Tungsten's high melting temperature suits this role, but conventional manufacturing limits complex geometries.

EBM enables printing tungsten with intricate features like deep slots, offering a simpler path to components that could advance nuclear fusion.

Watch the episode for details on this application. https://www.additivemanufacturing.media/articles/3d-printed-tungsten-diverter-tiles-for-nuclear-fusion-the-cool-parts-show-87

Compact machines are reducing cost, waste, physical footprint, and barriers to entry in additive manufacturing operation...
04/28/2026

Compact machines are reducing cost, waste, physical footprint, and barriers to entry in additive manufacturing operations.

As manufacturers integrate AM, demand rises for accessible, affordable equipment. Here are four examples encountered at RAPID + TCT:

- HP Multi Jet 1200: This under-$60,000 MJF platform offers 12-liter build capacity, saving prototyping time, space, and cost. It includes powder handling for automated unpacking and material mixing, enabling 22-hour production cycles while protecting intellectual property.

- MFI HZ-6: A 6-liter centrifugal barrel tumbler with a 3x2 ft footprint provides quiet, high-polished isotropic finishes on AM parts, using centrifugal force for quick burr removal and surface polishing.

- Mastrex MX-100: This desktop LPBF system, priced under $40,000, supports cost-effective metal printing for small parts, with a 4x3" build plate and layer heights from 20-60 microns.

- BMF MicroArch S150 and S150 Ultra: These 25-micron resolution tabletop printers, under $60,000, enable micro-precision for applications like endoscope shells and microneedles, with the Ultra model up to nine times faster.

Read the full article for details. https://www.additivemanufacturing.media/articles/4-small-machines-for-simpler-integration-of-additive-manufacturing

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