Formnext Awards – setting the stage for AM progress

Research-grade, xeno-free bio-ink for 3D Printing of human tissue models

TissuePrint is a research-grade, xeno-free bioink designed for printing human tissue models. It has been shown to maintain high levels of cellular viability post-printing (>90%) and can be used with a wide variety of delicate cells such as: pluripotent, endothelial, cardiac, mesenchymal, and spermatogonial cell types. 

While other inks on the market are only compatible with one type of bioprinter – ours have been optimized for use on multiple types of bioprinters. TissuePrint has been beta-tested for years to maximize customer ease-of-use, and therefore greatly reduces the time and money costs associated with creating home-made bioink formulations. All of our products are quality tested for sterility and reliability.

Axolotl Bioscience at Formnext Start-up Area: Hall 11.0, D62F

3D-printed interior components for aircraft

AM Craft is an EASA authorized Part 21G aviation supplier that leverages expertise in polymer Additive Manufacturing, design, airworthiness certification, and a distributed production network to ensure customers have the right part, at the right time, in the right location. We design printable parts to solve supply chain problems such as frequent breakage or long lead time. 

Once that problem has been solved for one airline, the design lives on in our digital warehouse ready to be produced again for any customer facing a similar challenge. 

AM Craft’s distributed production network combines in-house manufacturing and independent local production partners under a unified certification umbrella to bring flight part production to the point of need.  

Headquartered in Riga, Latvia, AM Craft operates in major aviation hubs in Europe, the Middle East, and Asia serving a global customer base.

AM Craft at Formnext Start-up Area: Hall 11.0, D62E

The amsight software redefines quality management and analytics in industrial 3D Printing. The award-winning software reduces the quality management costs by 70 % through automation of quality management tasks as well as its unique AI-based process optimization capabilities.

Amsight at Formnext: Hall 12.1, B39C

Development of resin-based SLA 3D print

micro factory 3DSolutions GmbH specializes in developing resin-based SLA 3D printers with full process. Our flagship product, a fully automated MSLA 3D printer, streamlines the entire printing process, including washing and post-curing, ensuring user safety and reducing manual labor. Designed for precision, speed, and flexibility, the printer enables the production of high-quality dental models and audiology applications and many more. With validated materials and established pilot partnerships, micro factory offers a reliable solution for all aiming to enhance efficiency and maintain consistent output.

micro factory is pioneering in Resin-based 3D Printing by launching a desktop machine that automates printing, washing, and curing. Our innovation enhances safety by containing hazardous materials and offers scalability for mass production, all managed via cloud connectivity.

Key Features

• Our unique desktop-sized machine combines all three steps of the MSLA 3D Printing process, offering unparalleled convenience and safety.
• Beyond automation, our proprietary technology fully encloses the printing process, protecting you from harmful materials.
• Our Cloud-based platform enables you to manage print jobs from anywhere, at any time. Coupled with our full automation, you can set your projects and forget them, as our machine handles it all.
• micro factory also isn’t just a one-off wonder. It’s designed for scalability. Build your own print farm and transition effortlessly from prototyping to mass production.
• With closed-loop sensor monitoring, we ensure maximum process reliability.
• With a machine prize of less than 30.000€ micro factory sets standards for affordable production setups.

micro factory at Formnext: Hall 11.1, E62

After two years, we are excited to announce the successful conclusion of our Technology Adoption Program. We’ve achieved significant milestones, such as collaborating with 20 innovative companies, developing high-quality and cost-effective solutions, and creating a material portfolio with thermoplastic properties. Building on this success, we’re proud to unveil our first VLM Production Platform at Formnext 2024. 

Our technology is able to unlock an unparalleled range of material properties for different applications across diverse vertical markets, including Automotive, Aerospace, Footwear and Defense & Space. Our materials portfolio, unmatched by any other AM technology thanks to its ability to process high viscous materials, ranges from rigid composites that combine mechanical and thermal properties to functional elastomers with properties comparable to EPDM or silicones.    

Supernova at Formnext: Hall 12.1, C62 and at the Formnext Start-up Area: Hall 11.0, D62J

Additively manufactured aortic valve designed to revolutionize the treatment of aortic valve stenosis 

Oryx Medicals is developing an innovative, additively manufactured aortic valve designed to revolutionize the treatment of aortic valve stenosis. Our product is a 3D-printed, patient-specific mechanical heart valve that combines the durability of traditional mechanical valves with the benefits of the minimally invasive Transcatheter Aortic Valve Implantation (TAVI) procedure.

Traditional mechanical heart valves require open-heart surgery (SAVR), which is highly invasive and risky, especially for older or less healthy patients. Although mechanical valves have a long lifespan, the surgical procedure presents significant challenges, including extended recovery time, higher costs, and lifelong anticoagulation therapy. On the other hand, biological valves can be implanted using the less invasive TAVI procedure but have a much shorter lifespan, often requiring re-operations within 10 years.

Our solution bridges this gap. The Oryx Medicals valve can be implanted using TAVI, offering a long-lasting, minimally invasive option that significantly reduces recovery time and the risk of complications. By using advanced Additive Manufacturing technologies, our valves are not only durable but also patient-specific. Each valve is tailored to the individual’s anatomy, enhancing the fit and performance while reducing potential complications such as leakage or thrombosis. The customized design is based on medical imaging data, allowing precise adaptation to each patient’s unique cardiovascular structure.

Key features of our product include:

• Long lifespan: Like traditional mechanical valves, our valve is designed to last a lifetime, significantly reducing the need for re-operations.
• Minimally invasive implantation: The valve can be implanted via the TAVI procedure, avoiding the risks and complications of open-heart surgery.
• Patient-specific design: The valve is 3D-printed to match the patient's specific anatomy, optimizing fit and function.
• Improved recovery and reduced costs: Faster recovery times and reduced hospital stays translate to lower overall healthcare costs and less strain on the healthcare system.

The Additive Manufacturing process enables us to create complex structures that mimic the physiological behavior of natural heart valves, improving both biocompatibility and hemodynamic performance. This ensures that the valve operates more efficiently, reduces mechanical stress on blood cells, and minimizes the risk of thrombosis or hemolysis.

Oryx Medicals at Formnext Awards Showcase: Hall 11.0, F61

Customized 3D-printed dental splint simplifies and enhances oral hygiene by using a unique water-air mixture 

At Enki Interdentalis, we are developing an innovative solution to clean your teeth. Our customized 3D-printed dental splint simplifies and enhances oral hygiene by using a unique water-air mixture to remove food particles and plaque from interdental spaces. This method offers a faster, easier, and more efficient cleaning experience than traditional dental floss or interdental brushes.

The technical design of the Enki system is divided into three main components, each contributing to the overall functionality and efficiency in cleaning the gaps between your teeth (interdental spaces).

The 3D-printed splint is crucial to the cleaning effectiveness. Each splint is a custom design based on a patient’s dental scan. The splint features a carefully crafted channel system that distributes pressure evenly across all interdental spaces. We optimize the design through fluid-mechanical simulations and physical prototypes. 

The nozzles – which line the inside of the splint facing the teeth – play a vital role in the safety and efficiency of the cleaning process. The orientation and shape of the nozzles lead to precise spray angles and are tailored to reach interdental spaces effectively without damaging the surrounding gum tissue. The nozzle design also enables easy cleaning, preventing calcification and other forms of contamination.

The water-air compressor works in close coordination with the channel system and nozzles of the Enki splint. The compressor is specifically engineered to generate microdroplets from a water-air mixture, delivering higher momentum than just a water jet stream. These accelerated droplets act like projectiles driven by an airstream, applying targeted pressure to penetrate biofilm, effectively removing it by concentrating force in key areas.

With a combination of these three components, the Enki system will clean all interdental spaces of the user in just three seconds. This will be especially valuable for caregivers and dental professionals working with patients who are unable to floss their teeth due to physical limitations.     

Enki Interdentalis at Formnext Awards Showcase: Hall 11.0, F61

A multi-material Additive Manufacturing solution based on the metal powder bed fusion process 

Tooth loss is a widespread disease of civilization, and the number of well-trained dental technicians is declining. However, high-quality restorative solutions for the remaining dentition are still often handmade, which makes them very expensive and inaccessible. 

These telescopic dentures consist of two different metal alloys underneath the veneer, which makes their production so complicated: a cobalt-chromium alloy for stability, and a gold alloy to ensure a secure fit in the patient's mouth.

Industrial production of dentures is currently limited to low-cost solutions such as clasp dentures or non-precious metal restorations. With many dental technicians retiring and an aging population, Europe is facing a gap in the supply of high-quality dentures. 

We have developed a multi-material Additive Manufacturing solution based on the metal powder bed fusion process, which enables the simultaneous processing of two (and more) different alloys in a single component. A robotic arm is used to insert the additional materials into the powder bed. Extensive expertise also includes the laser and scanning parameters to fuse the different materials and produce fully dense, high-fidelity parts. Thanks to a fully integrated digital process chain, the functional surfaces of the printed dental telescopes are automatically processed on the basis of a single data model. 

We create synergies with dental technicians, improving their efficiency and allowing them to focus on their core activities. The dental technician designs the prosthesis, we receive a digital model, manufacture the prosthesis and send it back to the dentist for finishing and delivery. This automated, made-to-order process reduces production time, increases laboratory throughput and eliminates unprofitable steps.

Fidentis at Formnext Awards Showcase: Hall 11.0, F61

Unique process of binder- and sinter-based Additive Manufacturing of cemented carbides

CERATIZIT Austria GmbH in Reutte, Tyrol, Austria, has developed a unique process of binder- and sinter-based Additive Manufacturing of cemented carbides. Cemented carbide, a composite of particularly hard but fragile tungsten carbide particles bound by ductile metal, such as cobalt, is an extreme material that is used when even the hardest steels fail in cutting tools or wear parts applications. However, the outperformance is offset by a complex process chain that also results in high CO2 emissions.

While the Austrian federal state of Tyrol already produces more sustainable energy than it consumes (source: www.statistik.at), the CERATIZIT Group uses 100% renewable energy, and its goal is to be CO2 neutral by 2025 (1). We have also commercialised the first cemented carbide grade ‘upGRADE CT- GS20Y’ that is made from >99% reprocessed materials, thus reducing the material-related CO2 footprint by 65-80%.

Thanks to our in-house developed FFF (Fused Filament Fabrication) process, we benefit from all the advantages of Additive Manufacturing in terms of material savings resulting from printing near-net shape and inner hollow structures. Looking at our example of a kneading paddle, 91% of the raw material is saved compared to conventional forming from a pre-sintered block. Since the process can be used to print all conventional grades, it is also possible to print upGRADE, resulting in a total CO2 reduction of more than 95%.

This breakthrough in the grade portfolio also enables Additive Manufacturing for cutting applications which could not be served until now. The possibility of printing inner structures offers additional potential for new functionalities. In the specific case of the kneader, it can be flooded with thermal fluid to enhance temperature control upon the kneading process.

Because of the very high density of the material, ranging from approx. 14 to 15 g/cm³, the resulting weight reduction aids in terms of transportation and applications with high kinetics, such as stamping, milling, moving valves, etc., to reduce the CO2 footprint of post-production in related processes. The very high wear resistance enhances the weight-to-lifetime ratio, making it more efficient and productive.

Since conventional grades are used, reprocessing of scrap can be done very efficiently. Within the CERATIZIT Group, recycling is done by direct re-use, re-use after burnout of organic components, Zinc-reprocessing of sintered scrap and chemical recycling of any contaminated scrap. Within the FFF process chain, we reclaim nearly 100% of the material.

(1) By 2025: Carbon neutral, emissions reduced by 35%
By 2030: Combined reduction of 60%
By 2040: Net zero, emissions reduced by 90%

Ceratizit at Formnext: Hall 11.1., F19

Social and Environmental LCA on Gas Turbine components made by Additive Manufacturing (L-PBF technology) in Baker Hughes

Baker Hughes, as an energy technology company, is committed to achieve a 50% reduction in CO2 emissions from own operations by 2030 and net zero by 2050, respect to 2019 baseline.

This ambitious initiative involves transforming the production of gas turbine components, transitioning from traditional casting methods to advanced Additive Manufacturing techniques. This shift not only aims to enhance the efficiency and durability of gas turbines but also represents a critical step in reducing environmental Impact within the energy sector.

By pioneering these innovative approaches, Baker Hughes is setting a benchmark for sustainability and technological advancement in the industry. This work focused on Gas Turbine components made by Nickel based alloys in investment casting, with the purpose to analyze them with a comparative LCA between casting and additive technology.

The main challenge of the project was to evaluate the environmental and social performance of background processes, finding main drivers and negligible parameters to simplify decision maker's choices. Moving production to Additive Manufacturing can reduce CO2e emissions by 16% to 38%, depending on the application. L-PBF technology can positively Impact both new and service units through upgrades. The same approach could be applied to any casting components, beyond the gas turbine sector.

This work addresses four among the seventeen United Nation sustainable development goals (SDGs): affordable and clean energy (SDG 7), decent work and economic growth (SDG 8), responsible consumption and production (SDG 12), and finally climate action (SDG 13).

Investing in the assessment, reporting, and enhancement of a product's environmental and social performance propels companies toward energizing sustainable changes.

Baker Hughes at Formnext Awards Showcase

Unique process of binder- and sinter-based Additive Manufacturing of cemented carbides

CERATIZIT Austria GmbH in Reutte, Tyrol, Austria, has developed a unique process of binder- and sinter-based Additive Manufacturing of cemented carbides. Cemented carbide, a composite of particularly hard but fragile tungsten carbide particles bound by ductile metal, such as cobalt, is an extreme material that is used when even the hardest steels fail in cutting tools or wear parts applications. However, the outperformance is offset by a complex process chain that also results in high CO2 emissions.

While the Austrian federal state of Tyrol already produces more sustainable energy than it consumes (source: www.statistik.at), the CERATIZIT Group uses 100% renewable energy, and its goal is to be CO2 neutral by 2025 (1). We have also commercialised the first cemented carbide grade ‘upGRADE CT- GS20Y’ that is made from >99% reprocessed materials, thus reducing the material-related CO2 footprint by 65-80%.

Thanks to our in-house developed FFF (Fused Filament Fabrication) process, we benefit from all the advantages of Additive Manufacturing in terms of material savings resulting from printing near-net shape and inner hollow structures. Looking at our example of a kneading paddle, 91% of the raw material is saved compared to conventional forming from a pre-sintered block. Since the process can be used to print all conventional grades, it is also possible to print upGRADE, resulting in a total CO2 reduction of more than 95%.

This breakthrough in the grade portfolio also enables Additive Manufacturing for cutting applications which could not be served until now. The possibility of printing inner structures offers additional potential for new functionalities. In the specific case of the kneader, it can be flooded with thermal fluid to enhance temperature control upon the kneading process.

Because of the very high density of the material, ranging from approx. 14 to 15 g/cm³, the resulting weight reduction aids in terms of transportation and applications with high kinetics, such as stamping, milling, moving valves, etc., to reduce the CO2 footprint of post-production in related processes. The very high wear resistance enhances the weight-to-lifetime ratio, making it more efficient and productive.

Since conventional grades are used, reprocessing of scrap can be done very efficiently. Within the CERATIZIT Group, recycling is done by direct re-use, re-use after burnout of organic components, Zinc-reprocessing of sintered scrap and chemical recycling of any contaminated scrap. Within the FFF process chain, we reclaim nearly 100% of the material.

(1) By 2025: Carbon neutral, emissions reduced by 35%
By 2030: Combined reduction of 60%
By 2040: Net zero, emissions reduced by 90%

Ceratizit at Formnext: Hall 11.1., F19

Holistically sustainable production of high-quality footwear in the luxury segment

At the heart of our sustainability commitment is a collaborative, data-driven approach that prioritizes the needs of our users in implementing 3D Printing solutions.

We are excited to share insights from our recent Sustainability Life Cycle Inventory (LCI), titled “Comparative Analysis: 3D Material Jetting vs. Traditional Methods for Designing Luxury Goods.” 

This study evaluates the use of Stratasys’ J850 TechStyle™ for producing 1,600 units of a luxury footwear applique by Dyloan Bond Factory, part of the Pattern Group.

Conducted by Reeves Insight and peer-reviewed by the Aachen Center for Additive Manufacturing (ACAM), the study highlights how Additive Manufacturing can significantly reduce emissions and conserve resources compared to traditional injection molding.

The fashion industry faces serious environmental challenges, and companies are eager to innovate while minimizing their impact on the planet. With the support of Stratasys technology, Dyloan and the Pattern Group are streamlining their supply chains, improving emissions, and reducing reliance on natural resources for better sustainability outcomes.

Key findings from the LCI include:

• Electricity Reduction: 64.3% lower electrical consumption.
• Emissions Reduction: 25% fewer emissions compared to traditional methods, saving one metric ton of CO2e during production.
• Supply Chain Optimization: Reduced from four technologies to one, cutting down on logistical impacts.
• Material Savings: 49.9% savings on stock material and 50% less material used in the final product.
• Water Conservation: Over 300,000 liters of water saved, primarily from eliminating paper-backed materials.

These results demonstrate the potential of Additive Manufacturing to advance sustainability in the fashion industry, with no compromise on innovation and elegance.

Stratasys at Formnext: Hall 12.1., D121

Siemens at Formnext: Hall 12.1. D101 and Formnext Awards Showcase: Hall 11.0, F61

Marinaressa Coral Tree demonstrates the potential of using AM in fabricating lightweight concrete structures 

The Marinaressa Coral Tree is a 3.2 m high filigree concrete structure designed for the Venice Architecture Biennale 2023. It demonstrates the potential of using Additive Manufacturing in fabricating lightweight concrete structures, particularly their formwork, to improve their sustainability and resource efficiency. 

The design solution is a topologically optimized construction detail of the transition zone from flat slab to column via a capital, whose weight has been reduced by distributing the material according to the stress state under load. Using computational design and optimization techniques, this was materialized as a spatial lattice aligned along the main stress trajectories to minimize cross-sections and maximize stiffness.

For the sustainable production of this structure, recyclable formwork technology has been developed. It is based on powder bed 3D Printing of a specially developed water-soluble mixture of silica sand and organic binder (dextrin). This combination allowed us to produce spatially complex, filigree geometries while avoiding waste during production. During 3D Printing, the binder in the powder mixture is activated by a jet of distilled water fed through a DoD print-head and immediately cured by infrared heaters. 

In this way, the formwork becomes geometrically stable and is able to withstand the hydrostatic pressure of the concrete during pouring and curing. At the same time, the formwork remains water-soluble and can be easily washed off during demolding and recycled. Thus, 56 sand formworks for 9 concrete modules were produced on a specially designed 3D printer with a powder bed volume of 1000 x 700 x 450 mm³. 

Then they were assembled, the reinforcement and connecting elements were integrated and the formworks were cast. After concrete curing, the formworks were washed off with water and the sand-binder mix was dried, pulverized and reused within the same production cycle.

This technology has allowed us to explore innovative structural forms such as stress-oriented spatial lattices and achieve a lightweight structural solution with 60% material savings without manufacturing waste. The design approach is based on the integration of computational design and optimization with additive manufacturing from the earliest stages of design development. This helps achieve lightweight, design solutions that can be realized with minimal environmental footprint, contributing to the decarbonization of the construction industry.

ILEK, ISW, University of Stuttgart at Formnext Awards Showcase: Hall 11.0, F61

The Quatro – a revolutionary new design that showcases the transformative power of AM

Quorum has developed a patented new product called “The Quatro.” The Quatro is a revolutionary new design that will allow a user to have additional adjustability, comfort, performance and efficiency that is not available with existing sockets. A socket refers to the portion of a prosthesis that fits around and secures an individual's limb and to which prosthetic components, such as a foot, are attached. There are a lot of existing prosthetic sockets that are effective at capturing and stabilizing a residual bone. However, the same rigidity and control makes it tougher for many patients to don their socket. Many amputees spend over ten minutes struggling to attach a socket to a swollen limb. 

The Quatro addresses this problem by utilizing “longitudinal compression” to better secure the device to a patient’s limb. What this means is we use vertical pads, located around the device to compress in and out, through the turn of a dial. A patient can wake up in the morning, when limbs are often swollen and unable to fit in traditional rigid sockets, and simply turn the dial to increase the allowable volume of the Quatro. They can insert their limb and secure the device in as little as twenty seconds.

Our project reimagines the capabilities of additive manufacturing by combining cutting-edge design aesthetics with optimized functionality. The concept centers around an innovative socket mechanism, designed to offer maximum adaptability to user needs and requirements. By utilizing advanced geometric algorithms, our design allows for easy customization, ensuring an ergonomic fit for diverse users while minimizing material waste.

The core element of the design is its modular structure, which supports a wide range of configurations to accommodate various medical conditions and treatment stages. The design not only provides enhanced patient comfort but also significantly improves the manufacturability and economic feasibility of socket solutions through the use of 3D Printing technologies.

Key advantages include: lightweight materials, volume adjustability, consistent manufacturing, and customization of design and features. 

We believe that this design showcases the transformative power of Additive Manufacturing, not only in terms of aesthetic creativity, but also in solving real-world challenges efficiently and sustainably.

Quorum Orthopedics at Formnext Awards Showcase: Hall 11.0, F61

By combining multiple materials in one process, we simplify the manufacturing chain and eliminate the need for traditional methods such as molding and stamping. This not only streamlines production but also reduces the assembly requirements. Our process is particularly suited for small-batch production, allowing cell developers to quickly adapt designs during early development stages without investing in new tooling. This agility is crucial in the fast-paced progress of next-generation battery cells, where rapid prototyping and design adjustments are essential. By enabling faster iterations and shorter lead times, our technique accelerates the path from design to market, helping to bring new battery technologies to life.

The capability to process ceramics as electrical insulator material alongside conductive metals by multi-material powder bed fusion is a unique aspect of our technique. A comparably high ceramic density is achieved without the need for high preheating, ensuring the structural integrity of the final product. While the current process still involves a relatively long build time and requires post-processing through milling, the benefits of design flexibility and supply agility make it a powerful alternative to traditional methods. This innovation holds the potential to transform how battery cell housings are manufactured, paving the way for more advanced, customizable, and efficient energy storage solutions.

With our submission for the (R)Evolution Award, we aim to share this groundbreaking technology with a global audience, showcasing its potential to redefine the standards in Additive Manufacturing. We believe this process marks a significant step in the evolution of battery cell production, unlocking new geometric possibilities in energy storage design. This multi-material process suits applications requiring composites with tailored electrical, thermal, and mechanical properties, including energy storage, electronics, aerospace, and biomedical devices. It allows for custom components, supporting advanced circuits, lightweight structures, and implants.

Fraunhofer IGCV at Formnext: Hall 11.0, D31 and at the Formnext Awards Showcase: Hall 11.0, F61

Multi-Laser Patterning (MLP) module – a revolution in exposure technology

The Multi-Laser Patterning (MLP) module is the flagship product from AMSYSTEMS, a revolution in exposure technology. The patented design of our MLP modules exploits the combination of multiple tightly focussed laser beams, to provide both high resolution and high productivity at any size build volume. These modules empower resin printing OEMs to create the next generation of industrial machines, capable of high quality, high volume production.

Powered by precision, at the heart of every MLP module is an octagonal prism that makes our process possible. But this heart doesn’t beat, it spins. Sitting on high-speed air bearings, the spinning of this polygon allows the laser from each diode fired through it to obtain a surface scanning speed of over 20 m/s, whilst maintaining a perpendicular interaction with the resin surface. With 20-micron spots on the resin surface, our precise encoders and nanosecond laser response times ensure we accurately and repeatedly target only the locations we desire.

With the Multi-Laser Patterning module, AMSYSTEMS is setting the stage for the future of industrial-scale 3D Printing. OEMs and end‑users can find us at Formnext or connect with us online, through our website or LinkedIn, to be part of this revolution.

AMSYSTEMS at Formnext: Hall 12.1, C59 and at the Formnext Awards Showcase: Hall 11.0, F61

Efficient removal of support structures in metallic 3D-printed components using dry ice blasting

The dry ice blasting system will revolutionize the market. Competitors who continue to rely on manual methods will face increasing pressure, as these processes are becoming outdated, especially in industries like aerospace and semiconductors. For our customers, this means a significant optimization of workflows. 

Previously, manual removal of support structures was time-consuming and led to quality inconsistencies, negatively affecting production line efficiency. Our system now industrializes this process, making it efficient and nearly human-free, reducing bottlenecks and quality issues, and boosting overall productivity. While our system can reduce cycle time by up to 15 minutes per part, its real value lies in the process reliability and ergonomic improvements.

The system is revolutionary, radically transforming the removal of support structures. It replaces the laborious, risky manual methods with a semi-automated process, improving ergonomics and reliability. Evolutionarily, it refines existing technologies for enhanced performance.

Unlike other market solutions that use chisels and compressors, risking part damage, our dry ice blasting system offers a major advancement. It replaces manual, strenuous methods with a partially automated process, reducing physical strain and enhancing ergonomic conditions while minimizing part damage.

No special knowledge is needed for the dry ice blasting system, the operator should be able to fully operate the system within a week. 

The project encompasses the formulation of novel ceramic-filled resins and the design of high-precision bone implants, optimized for DLP Stereolithography. We develop new bone implant designs and refine the parameters for Additive Manufacturing to achieve superior resolution and print quality.

Throughout the project, we document our findings with SEM and digital light microscopy, rheological data, surface topography graphs, XRD results and lists of optimum printing parameters. Our results are shared with students through master's and bachelor's programs in lectures and training, and with industry partners (e.g., Rahn AG, Chemische Fabrik Budenheim, BYK) and dental surgeons, contributing to the broader adoption of advanced Additive Manufacturing in bone regeneration application. Additionally, we publish our findings in peer-reviewed scientific journals, ensuring the dissemination of our research to the wider scientific community.

University of Stuttgart at the Formnext Awards Showcase: Hall 11.0, F61

A show that aims to inspire and educate, telling the story of Additive Manufacturing

3D Printing Nerd is a show that aims to inspire and educate while having fun. For over five years the show has travelled the world telling the story of Additive Manufacturing. From restoring history in Malta to creating the next level of energy production with Siemens, from 3D Printing in outer space with NASA to teaching celebrities like Neil Patrick Harris how to print, the show has run the gambit of all things additive. 

Every single week an episode of 3D Printing Nerd airs and gives viewers around the globe a view into the future. Episodes range from tutorials on software or machine walk throughs, to massive builds, to interviews with the experts and veterans of the industry. The show works with education programs helping them get access to resources that allow their programs to grow and thrive. 3D Printing Nerd also works with several non-profits and every year, teams up with Seattle Children’s Hospital to help raise funds for their programming.

Currently the show 3D Printing Nerd tapes in a 3,000 sq ft stage with multiple sets and also houses a fully functioning print farm. Guests from all over fly in to join Joel Telling, the host of the show and bring in their unique story of additive.

The show also works with all of the events around the world, bringing in new audiences to additive and giving them a chance to meet the companies and engineers that are pushing the industry forward. From LIVE shows from the floor of Formnext to hosting a game show in Manchester at SMRRF, 3D Printing Nerd is giving everyone a chance to participate in the next Industrial Revolution… as it’s happening first hand!

3D Printing Nerd is telling the story of additive like never before and bringing in millions each year into the world of manufacturing. It’s been my honor to produce this show and also work with one of my best friends as we get to travel the world and tell this very important story as its taking place.

You can experience 3D Printing Nerd live at Formnext on 19 November 2024, 3 – 5 p.m. in hall 12.1., C10 or follow him on YouTube.

Lastly, leading a team and Additive Manufacturing operation, he made prototyping quick and easy to access for thousands of employees. With his team, they redesigned the Do It Yourself (DIY) 3D printing lab to make the training, certification, and data management process an online, self-paced, process that takes less than an hour, giving people access to use industrial machines in almost no time at all. With this lowered barrier to entry, it made it possible for people to enter the lab with a problem and leave on the same day with a solution, leading to a large increase in lab usage and independent additive engagement.

These three systems work intertwined to drive technology adoption from both the top down and bottom up, ensuring Additive Manufacturing use remains both effective and culturally engrained. Large scale adoption, such as this, drives the industry forward by creating more users and advocates for the technology.