3D Printing Materials

With the funding from the European Union, the University of Cyprus (UCY) is spearheading the establishment of the Additive Manufacturing and Advanced Materials Competence Centre (AM2C3).  Although the funding amount is undisclosed, this initiative brings together expertise from Cyprus, Norway, Switzerland, and Spain. Partners in the project include Norway’s Foundation of Industrial and Technical Research (SINTEF), the Swiss Federal Laboratories for Materials Science and Technology (EMPA), and Spain’s IMDEA Materials Institute with Dr. María Teresa Pérez-Prado, head of the Sustainable Metallurgy Research Group, will work closely with UCY researchers leading IMDEA’s contributions. Together, these organizations will develop advanced methodologies and characterisation techniques for Al-MMCs, which are known for their strength-to-weight ratios and suitability for high-value aerospace applications. IMDEA Materials team. Photo via IMDEA Materials. A hub for advanced materials By creating a hub for innovation, this project aims to address growing aerospace industry demands for low-volume, high-performance material solutions. In…    read more 

Researchers at the Department of Energy’s Oak Ridge National Laboratory (ORNL) and the University of Maine have developed a groundbreaking single-piece, recyclable natural-material floor panel through advanced 3D printing techniques. This novel panel, designed to substitute traditional steel in construction, was unveiled at the U.S. Department of Housing and Urban Development’s 2024 Housing Innovation Showcase on the National Mall. The project is a key initiative under the Sustainable Materials & Manufacturing Alliance for Renewable Technologies (SM2ART) program, which focuses on creating environmentally friendly construction solutions. The SM2ART Nfloor cassette panel represents a significant advancement in building construction, particularly for apartment and condominium structures. By replacing conventional steel-and-concrete assemblies, the panel offers a sustainable alternative that maintains structural integrity while reducing environmental impact. Katie Copenhaver, a researcher at ORNL, emphasized the ecological benefits, stating, “By utilizing bio-based, large-scale 3D printing, we replaced an assembly made from 31 parts and three materials…    read more 

FormNext 2024 in Frankfurt recorded more than 34,000 visitors and saw new product introductions amid an increasingly consolidated additive manufacturing market. PowderMonkeys, a brand of Launhardt GmbH that specializes in polymer powders for powder bed fusion (PBF) processes, presented two new materials designed to improve performance and sustainability in 3D printing. PowderMonkeys, established in 2021 and a regular exhibitor at FormNext, supplies both desktop and industrial-scale systems. The portfolio is known for materials compatible with selective laser sintering (SLS) and high-speed sintering (HSS) platforms developed by companies such as Voxeljet AG, a provider of large-format 3D printing technology. Existing offerings include Monkey TPU 50, a thermoplastic elastomer with UV resistance, biocompatibility, and variable Shore hardness levels. According to technical data, Monkey TPU 50 exhibits a low refreshing rate of around 20% and a spherical powder shape contributing to stable 3D print processes. Monkey TPU 50, PowderMonkeys’ flagship thermoplastic elastomer. Photo…    read more 

Engineers from the University of New Mexico (UNM), a public research institution recognized for its work in advanced construction materials, have patented a bendable concrete designed for 3D printing. Researchers in the Gerald May Department of Civil, Construction, and Environmental Engineering aimed to address brittleness, high labor costs, and dangers associated with traditional building methods. This new composite, classified as self-reinforced ultra-ductile cementitious material, may herald more resilient infrastructure while reducing dependence on steel bars and heavy machinery. Traditional concrete is renowned for its strength under compression but is inherently brittle, leading to frequent cracks and the need for regular maintenance in infrastructure such as sidewalks and bridges. Maryam Hojati, assistant professor in UNM’s Gerald May Department, highlighted this limitation as a primary motivation for their research. “Concrete by itself does not show any tensile properties,” Hojati explained. To address this, the team incorporated short polymer fibers into the concrete…    read more 

UK-based metal 3D printing powder manufacturer Metalysis installed three new Gen 1 units at its Discovery Centre in Catcliffe, Rotherham, increasing its first-stage research capabilities by a third.  These Gen 1 R&D systems are used in the first step of Metalysis’ Fray, Farthing, and Chen (FFC) Cambridge electrolysis method for producing 3D printable metal alloy powders. The process is scaled across the company’s Gen 1-4 units, with material output increasing from grams per machine run with the Gen 1, to tens of tonnes per annum via the Gen 4.  Metalysis’ new systems, which bring its total suite of Gen 1 units to 12, have been added in response to “unprecedented” demand from the high entropy alloy (HEA) and commercial space sectors. They will be used to develop novel materials for advanced applications in hypersonics, defense, clean energy, and space  “We are delighted to be expanding Metalysis’ development capabilities by increasing…    read more