Additive Manufacturing has come a long way since Dr. Hideo Kodama first introduced the idea of printing via layers versus injection molding in 1981. Since then, there has been a steady stream of game-changing advancements that have led to the evolution of this new-age manufacturing process. Now, 3D Printing’s versatility is set to expand further thanks to some innovative concepts that are hitting the market. Here’s what you need to know.
Beyond Customization: The Expanding Capabilities of 3D Printing
3D printers are capable of much more than just creating customized shapes. Today’s 3D printers can print metal, new age composites, working electronics, and even human organs. All of these developments continue to lead to further innovations in the sector that push the tech further. Here are some recent advancements in 3D printing that could take the industry to the next level.
3D Printing in Robotics: A New Era of Actuators
When you think of 3D printed robotics, you probably envision a metal 3D printer churning out robotic pieces that get assembled further before they are functional. While this approach is entirely possible, it would only make sense if the robotics printed needed to be on a small production scale or a one-of-a-kind customization.
A better use for 3D printing in robotics is to create actuators. Actuators are the systems that operate when you move parts on a robot. They are usually made of some form of electric servo that operates when current is applied. The drawback of this approach is that servos are heavy, rigid, and add complexity to the devices.
Recognizing these limitations, a team from Empa’s Laboratory for Functional Polymers just released the Rapid Manufacturing of High-Permittivity Dielectric Elastomer Actuator Fibers1 study. This report highlights a novel approach to creating artificial muscles that operate as actuators for robots. The study explains how the new method eliminates the need for layer-by-layer batch production.
Dielectric Elastomer Actuators: Soft Robotics Advancements
The use of continuous co-extrusion-based manufacturing enables the 3D printer to create actuators that function while retaining the core principles, such as softness and elasticity, found in their human counterparts. Specifically, these units contract when voltage is applied and relax to an expanded state when not charged. This action is similar to how your muscles operate.
Source – Empa
Innovative Materials: The Dual-Ink Approach
The key to their development was the creation of a special type of printer and inks. The ink needed to easily liquify under certain conditions, but retain its shape, elasticity, and contractility when completed. The engineers integrated two different silicone-based materials.
One of the materials was a conductive electrode material. The other layer consisted of a non-conductive dielectric. The two were printed together at the same time. Notably, the materials didn’t mix and instead were printed in a cross-link pattern similar to if you had your fingers interlocked. Additionally, a special nozzle was developed to deliver the materials.
The result was an ultra-responsive actuator that weighs less than its predecessors and has no moving parts. The engineers noted that their actuators can be made in nearly any design to fit a huge range of applications. Additionally, they cost less to print and have a longer life expectancy than their servo counterparts.
Potential Applications: From Robotics to Medicine
There are several applications for this technology that span across many different sectors. Already, the engineers have discussed utilizing the tech to create thin, fully functional, high-permittivity fibers that could act as replacements for your human muscle fibers if injured.
In the future, you may see these inexpensive and reliable actuators used in automobiles, machinery, and other sectors that currently rely on outdated and inefficient alternatives. Now, the team seeks to lower production costs and discover new applications for this advanced 3D printing tech.
Growth Printing: A Nature-Inspired 3D Printing Method
Engineers from the Beckman Institute for Advanced Science and Technology recently introduced a nature-inspired 3D printing method that eliminates the need for specialty equipment or molds. The research paper Morphogenic Growth 3D Printing2 promises to lower 3D printing costs and enables faster manufacturing of customized parts using advanced polymers.
Growth printing is an exciting development that takes inspiration from the way trees grow over time. When you look at a tree, you may not be aware that its growth is a combination of its genetics and environment. Trees are constantly making minuscule adjustments in their growth to optimize their location.
Source – Beckman Institute
Each layer of tree growth is a calculated addition that helps to compensate for any restrictions in its location and enhance its beneficial aspects. This approach allows the tree to compensate during growth and achieve a higher degree of stability and durability.
The Reaction-Diffusion Process: A New Approach to 3D Printing
The newly created 3D printing method operates by utilizing the reaction-diffusion process. In this approach, 100g of liquid resin called dicyclopentadiene is placed into an open glass container measuring 65 × 65 × 65 mm3. The container is then submerged in a 110 × 110 × 110 mm3 beaker filled with ice water, and the center point of the resin is heated to 70 °C using a cartridge heater of 1/8 inch diameter and 2 inch length.
AI and Computational Modeling in Growth Printing
An advanced computer model helps to determine how to slowly lift the resin out of the heated jar in a manner that allows it to cool into certain shapes layer by layer. The software takes into account various factors and makes adjustments to the lifting process to achieve the intended shape.
Next, a robotic arm manipulates the extrusion head, bringing it out of the heated state into the cool surroundings and allowing it to harden in layers. These layers take into account gravity and other factors during each stage of their addition. As such, this method of 3D printing can create stronger designs that can withstand more pressure.
Notably, the engineers utilize the computer algorithm to determine the ideal cross-section design of the extrusion tip, the exact trajectories with angular motion of the tip, if multiple tips with merging fronts are required, and the resin viscosity.
Enhanced Precision in 3D Printing Through Reaction-Diffusion
Interestingly, the reaction-diffusion model allows engineers to predict the shape of the part precisely based on the motion of the heated tip. It also allows engineers to determine the easiest way to make a shape with minimal movements. Together, these advancements allow for faster 3D printing of certain designs.
Using a DSLR camera, the engineers captured side-view images of the process. This step helped the team fine-tune the temperature and other factors. Notably, the group used all glass beakers and a glass stand that allowed complete 360-degree monitoring. They found that their approach produced stronger prints faster.
Industrial and Scientific Applications of Growth Printing
There’s a lot of demand for faster 3D printing technology. 3D printers are great at making customized parts and short-run productions, but they take a while to complete. Even the best methods take hours to operate and cure. The ability to quickly print durable shapes and components will be a major plus to many industries.
3D Printing in Particle Physics: A Breakthrough in Scintillator Detectors
Additive manufacturing is now ready to delve into the quantum realm, thanks to a team of ingenuitive researchers from ETH Zurich. The group recently published a study titled “Additive manufacturing of a 3D-segmented plastic scintillator detector for tracking and calorimetry of elementary particles“3 that introduces a new way to create large-scale plastic scintillator detectors that could lower research costs for scientists in the future.
What is a Scintillator, and How is 3D Printing Improving It?
Scintillation material is commonly used in particle physics to create designs that can monitor neutron movements. These systems are one of the primary ways that researchers can detect ionizing radiation. Notably, these devices can track neutrons and determine the presence of x-rays, beta, and gamma rays. As such, they remain a vital component for scientists seeking to track these rays,
The SuperFGD and the Future of Particle Detection
The SuperFGD is the current standard for scintillators. SuperFGDs are very complex devices that can include millions of cubes, specially designed to detect and track charged particles. These devices operate by measuring energy loss as charged particles venture through the device. To accomplish this task, each cube has optical fiber embedded.
The problem is that it is incredibly expensive and time-consuming to manufacture these crucial devices. These costs continue to hinder adoption and restrict access to these devices. A new fused injection modeling (FIM) combines fused deposition modeling (FDM) and injection molding to create a more affordable alternative. However, it still lacks compared to recent 3D printed versions.
Introducing the SuperCube: A Cost-Effective Scintillator Alternative
To demonstrate their new design, the engineers created the SuperCube scintillator. This upgraded device features 125 optically isolated voxels that can track particle energy paths. The unit is arranged in a 5 × 5 × 5 configuration, with each voxel designed to hold two orthogonal wavelength-shifting fibres.
Notably, this approach provided performance on par with the SuperFGD but at a fraction of the costs. Notably, the manufacturing time for one voxel was estimated to be around 6 minutes, which is far less than current options. Additionally, the team seeks to reduce this time in half in the coming months.
Scientific Applications: From CERN to Space Exploration
The application for these devices includes scientific research at some of the most prestigious sites in the world. One day, these devices could operate in CERN and on satellites, where they will help to detect cosmic rays and other charged particles in real time.
What’s Next for 3D Printing? Emerging Innovations
There’s so much going on in the 3D printing sector currently. This year has seen additive manufacturing in space, using multiple materials, and even creating functional parts using complex material combinations. In the future, even more complex material interactions may be devised, allowing for working products to be printed in a single go. Here are a few more developments that will reshape the market in the coming months.
Holographic Direct Sound Printing (HDSP)
Engineers have created a method of printing through walls utilizing ultrasonic holography. The device uses these waves to organize shapes and harden them without any physical contact. This approach provides a method to print intricate designs and has some very impressive use case scenarios.
Imagine an astronaut replacing or repairing an aging part located in an area that would be nearly impossible to reach without days of labor. While this may seem impressive, it’s not as wowing as the thought of going to your doctor and getting an organ repaired without ever having to go to surgery. All of these scenarios could become possible thanks to the holographic 3D printing breakthroughs.
3D-Printed Homes: The Future of Affordable Housing and Space Colonization
There is a lot of effort being put into creating viable 3D-printed homes. This technology will lower the costs of housing here and usher in the possibility of colonizing space. Engineers envision the use of these printers to create habitats utilizing material native to the planet, reducing costs further.
This strategy makes sense when you consider it’s expensive to bring building materials into space. The best option is to utilize a purpose-built 3D printer for construction in these scenarios. Another 3D printer could also create specialty tools and other requirements to streamline the process.
The Rise of 4D Printing: Shape-Morphing Structures
Growth printing and other developments open the door for the 4D printing revolution. 4D printing refers to the printing of shape-morphing parts. Think of 4D printed parts as a print that enables 1D strands to transform into 3D shapes. 4D printing is seen as the future for many analysts who see it one day being able to create prosthetics that grow with the wearer or dissolve after they are no longer needed.
The Unmatched Versatility of 3D Printing
As 3D printing evolves, it has become the best option for many of today’s products. The flexibility and versatility of 3D printers allow engineers to continually think of new and exciting ways to create utilizing layer by layer methods. These latest developments are sure to push the envelope further and usher in a new age of 3D printing convenience.
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Studies Referenced:
1. Danner, P. M., Pleij, T., Liechti, F., Wolf, J., Bayles, A. V., Vermant, J., & Opris, D. M. (2025). Rapid manufacturing of high-permittivity dielectric elastomer actuator fibers. Advanced Materials Technologies. https://doi.org/10.1002/admt.202500190
2. Kim, Y. S., Zhu, M., Hossain, M. T., Sanders, D., Shah, R., Gao, Y., Geubelle, P. H., Ewoldt, R. H., & Tawfick, S. H. (2025). Morphogenic growth 3D printing. Advanced Materials, 37(12), Article 2406265. https://doi.org/10.1002/adma.202406265
3. Kieseler, J., & Canelli, F. (2025). Additive manufacturing of a 3D-segmented plastic scintillator detector for tracking and calorimetry of elementary particles. Communications Engineering, 4(1), Article 371. https://doi.org/10.1038/s44172-025-00371-z