Showing posts with label 3D printing. Show all posts
Showing posts with label 3D printing. Show all posts

Friday, April 10, 2026

Can This 3d printed, personalized “Living Knee” Revolutionize Joint Replacement due to osteoarhthrits?

Good news! This seems to be a promising approach! A company was already formed to commercialize this new orthopedic joint. It uses patient stem cells to build new cartilage.

"... to create a new biological knee joint that can last a lifetime, expand joint surgery to younger patients, and provide a better joint for all patients.

Two years into the project, ARPA-H has now given the team the green light to move into the second phase of development and begin preclinical testing of their “living knee” implant, called NOVAKnee. ...

“Our decades of research studying cartilage have shown that no other material has the same joint lubrication or load-bearing properties of articular cartilage. Based on this, we decided that we needed a strategy to regenerate a living knee, rather than simply replacing it,” ...

The Columbia design for this new joint looks like current metal and plastic replacement joints and will be surgically implanted with the same procedures. But NOVAKnee is a living, 3D-printed human organ, created with a biodegradable scaffolding material infused with stem cells. After implantation, the cells will regenerate the joint’s natural cartilage and bone tissues as the scaffold disappears. 

The team identified new biomaterials and used them to design an implant that can sustain the loading of the human knee. The implant contains combinations of biomaterials to make femoral- and tibial-shaped implants, sized to the patient’s knee. Then it gets seeded with cartilage and bone cells, derived from stem cells either from the patient’s own body (lipoaspirate from the abdomen) or from adult inducible pluripotent stem cells. ...

To accelerate this breakthrough technology's path to patients, NOVAJoint Orthopedics ... has been established as an independent company committed to commercializing the NOVAKnee implant and extending the technology across orthopedic applications. ..."


Can This “Living Knee” Revolutionize Joint Replacement? | Columbia University Irving Medical Center






Friday, January 30, 2026

Underwater 3D printing could transform maritime construction

Amazing stuff!

"Since it was invented in the 1980s, 3D printing has moved from the laboratory to the factory, the home and even outer space. 

Now, an interdisciplinary group of Cornell researchers is developing a way to bring the technology to the ocean. By 3D-printing concrete underwater, the new approach could transform on-site maritime construction and the repair of critical infrastructure that connects continents. ...

The project got its start in fall 2024, when the Department of Defense’s Defense Advanced Research Projects Agency (DARPA) issued a call for proposals to design 3D-printable concrete that could be deposited at a depth of several meters underwater – and to do so in a radically truncated timeframe of one year. ...

Underwater printing faces numerous challenges. Chief among them is preventing washout, in which cement particles fail to bind together during deposition, weakening the material. The typical solution is introducing admixture chemicals, but these create complications of their own. ...

DARPA added one more hurdle: The concrete needed to consist primarily of seafloor sediment and only include a small amount of cement. Incorporating material from the bottom of the ocean would minimize the logistical difficulty of transporting large quantities of cement by ship. ..."

Underwater 3D printing could transform maritime construction | Cornell Chronicle


For months, the team has been conducting test prints in a large tub of water, monitoring how the layers are deposited and the strength, shape and texture of each sample.


Saturday, January 17, 2026

World's fastest drone hits record breaking 408 mph (658 km/h) reclaimed by a son/father team from South Africa

The drone is custom made and 3D printed!

"...
Building the drone
3D printing enabled the father-son duo to rapidly build prototypes and switch things up when needed. The Peregreen V4 was made with Bambu Lab’s H2D high-speed dual-nozzle printer, allowing the team to combine different materials in a single print. ...

Given the fierce competition in this space, that record may not hold for long. We could see this record surpassed by a rival or by Luke and Mike Bell themselves. In any case, these record attempts are exciting to watch."

World's fastest drone hits record breaking 408 mph


The Peregreen V4 quadcopter has flown into the record books as the world's fastest drone


Tuesday, December 16, 2025

Europe's largest 3D-printed housing project builds one apartment per day in Denmark

Good news! The descendants of the Vikings at work! 😊

Housing shortages will be a thing of the past!

"Described as Europe's largest 3D-printed housing project, the Skovsporet development is currently underway in Denmark. A total of 36 student apartments were built with remarkable speed, as the cutting-edge technology allowed the equivalent of more than one apartment per day to be printed. ..."

Europe's largest 3D-printed housing project builds one apartment per day




Wednesday, December 03, 2025

3D-printed cornea restores blind patient's sight for the first time

Good news!

"In a major breakthrough in human tissue replication, for the first time ever a 3D-printed cornea has been transplanted onto a legally blind patient's eye, successfully restoring their sight. ..."

"In late October 2025, Rambam Eye Institute's Cornea Unit performed the world’s first transplantation of a fully 3D-bio-fabricated, cell-based corneal implant. The procedure was carried out on a patient who was legally blind in the treated eye, marking the first time anywhere that a corneal implant grown entirely from cultured human corneal cells, rather than donor tissue, has been successfully transplanted in a human being. In this instance, a single cornea from a healthy, deceased donor was cultured in the lab to create and print an additional 300 corneal implants. ..."

3D-printed cornea restores blind patient's sight for the first time





Friday, October 17, 2025

3D printing gradients unlocked for advanced engineering

Good news!

"... Engineers will have an easier time 3D printing objects out of multiple different materials with the release of an open-source tool, OpenVCAD, that can convert complex gradient designs into printer ready code for advanced engineering applications.

Designing and 3D printing gradients, where 2 materials gradually blend from one to another, is extremely difficult. ...

“This is the first multi-material, code-based design tool that is widely available. It allows for good complexity when printing objects, it’s accessible and it’s intuitive to write and design.”

Materials with continuous gradients, called ‘functionally graded materials’, can enhance the mechanical performance of materials, optimise weight distribution and eliminate sharp interfaces between materials where stress could concentrate in an object. ..."

From the abstract:
"This paper presents a novel gradient-informed slicing method for functionally graded additive manufacturing (FGM) that overcomes the limitations of conventional toolpath planning approaches, which struggle to produce truly continuous gradients.
By integrating multi-material gradients into the toolpath generation process, our method enables the fabrication of FGMs with complex gradients that vary seamlessly in any direction. We leverage OpenVCAD's implicit representation of geometry and material fields to directly extract iso-contours, enabling accurate, controlled gradient toolpaths.
Two novel strategies are introduced to integrate these gradients into the toolpath planning process.
The first strategy maintains traditional perimeter, skin, and infill structures subdivided by mixture ratios, with automated 'zippering' to mitigate stress concentrations.
The second strategy fills iso-contoured regions densely, printing directly against gradients to eliminate purging and reduce waste.
Both strategies accommodate gradually changing printing parameters, such as mixed filament ratios, toolhead switching, and variable nozzle temperatures for foaming materials.
This capability allows for controlled variation of composition, density, and other properties within a single build, expanding the design space for functionally graded parts. Experimental results demonstrate the fabrication of high-quality FGMs with complex, multi-axis gradients, highlighting the versatility of our method. We showcase the successful implementation of both strategies on a range of geometries and material combinations, demonstrating the potential of our approach to produce intricate and functional FGMs. This work provides a robust, open-source, and automated framework for designing and fabricating advanced FGMs, accelerating research in multi-material additive manufacturing."

3D printing gradients unlocked for advanced engineering




VCAD workflow: program → compile → export for printing or simulation.




Tuesday, June 24, 2025

3D-printed model of a 500-year-old prosthetic iron hand hints at life of a Renaissance amputee from Germany

Amazing stuff!

Since my childhood I have known of the marvelous iron hand of the German knight of Götz von Berlichingen (1480 - 1562 CE). I have seen this iron hand during my visit of the Museum der Burg Jagsthausen. This is not the same iron hand that was used for this study.

"... Yet, such artifacts are rare direct sources into the lives of historical amputees. We focus on the tools amputees used in 16th- and 17th-century Europe. There are few records written from amputees’ perspectives at that time, and those that exist say little about what everyday life with a prosthesis was like. ...

But computer-aided design software can help scholars reconstruct the artifacts’ internal mechanisms. This, in turn, helps us understand how the objects once moved. ...

For two years, my team of historians and engineers at Auburn University had worked tirelessly to turn an idea – recreating the mechanisms of a 16th-century artifact from Germany – into reality. The original iron prosthesis, the Kassel Hand, is one of approximately 35 from Renaissance Europe known today. ..."

3D-printed model of a 500-year-old prosthetic hand hints at life of a Renaissance amputee


The Kassel Hand Project

Liste Eiserner Hände (List of known mechanical iron hands of the 15th & 16th century CE. Strange, this Wikipedia entry is only available in German language)

The original Kassel hand


The 3D printed models

Two historical drawings of these mechanical, iron hands.





Thursday, May 15, 2025

3D Printing deep tissue In Vivo Using ultrasound

Amazing stuff!

"... Gao and his colleagues report their new in vivo 3D-printing technique in the journal Science. Along with bioadhesive gels and polymers for drug and cell delivery, the paper also describes the use of the technique for printing bioelectric hydrogels, which are polymers with embedded conductive materials for use in the internal monitoring of physiological vital signs as in electrocardiograms (ECGs).  ...

They came up with a novel approach: Combine ultrasound with low-temperature–sensitive liposomes. Such liposomes, spherical cell-like vesicles with protective fat layers, are often used for drug delivery. In the new work, the scientists loaded the liposomes with a crosslinking agent and embedded them in a polymer solution containing the monomers of the polymer they wanted to print, an imaging contrast agent that would reveal when the crosslinking had occurred, and the cargo they hoped to deliver—a therapeutic drug, for example. Additional components can be included, such as cells and conductive materials like carbon nanotubes or silver. The composite bioink was then injected directly into the body.

Raise the Temperature Just a Touch to Trigger Printing

The liposome particles are low-temperature sensitive, which means that by using focused ultrasound to raise the temperature of a small targeted region by about 5 degrees Celsius, the scientists can trigger the release of their payload and initiate the printing of polymers."

From the perspective abstract:
"Tailoring implants to an individual’s anatomy can offer better surgical outcomes and patient satisfaction.
Traditionally, patient-specific artificial components, such as breast implants or hip joints, are sculpted outside of a body and inserted by open surgery.
Additive manufacturing, or three-dimensional (3D) printing, offers an alternative to quickly build personalized implants with complex shapes. 3D printing using infrared light has enabled the patterning of complex shapes underneath submillimeter-thick skins or muscles. In this approach, irradiating tissue-embedded polymer inks with light triggers polymerization. However, considerable attenuation and scattering of light beams by intervening tissues limit direct printing of implants beneath millimeter-thick tissues. ... Davoodi et al. report 3D printing using ultrasound rather than light to create complex structures underneath centimeter thick tissues inside an animal body. This process could potentially be combined with conventional ultrasound imaging to customize the shapes of implants on demand."

From the editor's summary and abstract:
"Editor’s summary
Three-dimensional (3D) printing is a valuable tool for generating patient-specific implants, either externally or even directly inside the body. The limitation of the former approach is the need for surgical implantation, whereas the latter approach is limited by the need for precursor materials and a polymerization method safe for in vivo use that can be activated with precision from outside of the body. Davoodi et al. developed a platform that uses imaging-guided ultrasound printing, which is capable of penetration depths much greater than the other approaches (see the Perspective by Kuang). The authors loaded cross-linking agents loaded into low-temperature–sensitive liposomes for incorporation into tunable bioinks. In vivo demonstrations included printing near diseased areas in a mouse bladder and deep within rabbit leg muscles. ...

Abstract
Three-dimensional printing offers promise for patient-specific implants and therapies but is often limited by the need for invasive surgical procedures. To address this, we developed an imaging-guided deep tissue in vivo sound printing (DISP) platform. By incorporating cross-linking agent–loaded low-temperature–sensitive liposomes into bioinks, DISP enables precise, rapid, on-demand cross-linking of diverse functional biomaterials using focused ultrasound.
Gas vesicle–based ultrasound imaging provides real-time monitoring and allows for customized pattern creation in live animals.
We validated DISP by successfully printing near diseased areas in the mouse bladder and deep within rabbit leg muscles in vivo, demonstrating its potential for localized drug delivery and tissue replacement.
DISP’s ability to print conductive, drug-loaded, cell-laden, and bioadhesive biomaterials demonstrates its versatility for diverse biomedical applications."

3D Printing In Vivo Using Sound - www.caltech.edu "Imagine if doctors could precisely print miniature capsules capable of delivering cells needed for tissue repair exactly where they are needed inside a beating heart. A team of scientists led by Caltech has taken a significant step toward that ultimate goal, having developed a method for 3D printing polymers at specific locations deep within living animals. The technique relies on sound for localization and has already been used to print polymer capsules for selective drug delivery as well as glue-like polymers to seal internal wounds."

Replicating a tissue with sound waves (no public access)

Imaging-guided deep tissue in vivo sound printing (no public access, but this link provides access to PDF) "Ultrasound waves can penetrate thick tissues and print implants on demand inside a body"


The deep tissue in vivo sound printing (DISP) platform. The technique combines ultrasound with low-temperature–sensitive liposomes loaded with crosslinking agents. The liposomes, often used for drug delivery, are embedded in a polymer solution containing the monomers of the desired polymer, an imaging contrast agent that reveals when crosslinking has occurred (here, the gas vesicles used for this purpose are shown as hexagons), and the cargo they hope to deliver—a therapeutic drug, for example. Scientists use focused ultrasound to increase the temperature in a targeted area by a few degrees, causing the liposomes to release their contents and initiate printing in a precise location.





Tuesday, April 15, 2025

3D-printed skin could replace animal testing for cosmetics

Good news! Will this finally become reality!

I have been waiting for something like this to happen for several decades!

"While we're making progress in phasing out animal testing in the cosmetics industry around the world, there's still a ways to go in terms of regulatory measures (some 35 US states still allow it), international cooperation, and scientific advancements in developing reliable alternatives. 3D-printed 'imitation skin' could be the ticket.

Researchers from Austria's Graz University of Technology and the Vellore Institute of Technology in India have developed a way to 3D print hydrogel formulations along with living skin cells, that eventually develop into tissue you can use to test new cosmetics. ..."

"... A team of researchers from Graz University of Technology (TU Graz) and the Vellore Institute of Technology (VIT) in India is working on the development of skin imitations that mimic the native three-layer tissue structure and biomechanics of human skin. Such imitations can be produced using 3D printing and consist of hydrogel formulations that are printed together with living cells. The first skin models are now ready for nanoparticle testing. ...

TU Graz is working intensively on cross-linking methods for stabilisation. Ideally, following nature’s example, the cross-linking takes place under very mild conditions and without the use of cytotoxic chemicals. After successful stabilisation, the cooperation partners in India test the resistance and toxicity of the 3D prints in cell culture. Only when skin cells in the hydrogel survive in cell culture for two to three weeks and develop skin tissue can we speak of a skin imitation. This skin imitation can then be used for further cell tests on cosmetics. ... "

3D-printed skin could replace animal testing for cosmetics

Printed Skin to Replace Animal Testing (original news release) "A research team from TU Graz and the Vellore Institute of Technology in India is developing a 3D-printed skin imitation equipped with living cells in order to test nanoparticles from cosmetics without animal testing."


3D-printed structure made of optimised hydrogel.


Wednesday, January 29, 2025

Texas-Based Company Wins Pentagon Contract for 3D Printed Explosives

Explosive news!

"... SD&S has secured an initial $2 million Pentagon contract to develop and prove its cutting-edge 3D production system. ...

VLM, which will allow it to safely, cost effectively and consistently manufacture both conventional and innovative explosive material for use in artillery ammunition, solid rocket motors, aircraft bombs, pyrotechnics and small arms propellant. ..."

"VLM™ (Viscous Lithography Manufacturing) is a lithography-based additive manufacturing technique that uses a transparent film to transfer material onto a build platform, where they are cured by light to form 3D printed parts.

When applied to energetic materials, VLM™ offers an innovative approach to producing high-performance components. ..."

Texas-Based Company Wins Pentagon Contract for 3D Printed Explosives "The technology start-up “Supernova Defense & Space” based in Austin is developing a patented VLM-assisted 3D processes that will allow it to produce military grade energetic materials."




Sunday, January 26, 2025

First fully 3D Printed Microscope Could Bring Microscopy to Millions

Good news! What will the next child prodigy discover?

"“Researchers have designed and built the world’s first microscope made entirely from 3D-printed parts. And because the open-source plans are already available online, almost anyone can assemble their own for barely $60.

A few years ago, researchers at the University of Bath and University of Cambridge started the Open Flexure project offering open-source blueprints for 3D-printed microscopes. With its core development group now based at the University of Glasgow, OpenFlexure microscopes have been assembled in over 50 countries around the world, as well as at laboratories in Antarctica. While much cheaper than standard equipment, there was a caveat: a microscope’s specially crafted glass lenses often cost hundreds of dollars, putting the tools out of many people’s price range. Recently, however, a team at the University of Strathclyde developed a workaround they say both lowers the OpenFlexure design’s total cost, and makes it the first completely 3D-printed microscope.”"

"Scientists at the University of Strathclyde have created the world's first fully 3D printed microscope in under three hours and for less than £50 – a fraction of the cost of traditional devices.

Using a publicly available design from the website OpenFlexure the scientists produced the microscope’s frame – and clear plastic lenses they designed themselves – using low-cost, accessible 3D printers.

The microscope was completed by adding a shop-bought camera and a light, with the whole device controlled by a Raspberry Pi computer processor. ...

The microscope demonstrated sub-cellular resolution, clearly imaging individual red blood cells and detailed structures in the kidney sample. ..."

3D Printed Microscope Could Bring Microscopy to Millions - Human Progress




Monday, December 16, 2024

Turning 3D printing's biggest flaw into its smartest feature

Good news!

"... Known as voxel interface 3D printing, or VI3DP, the technique uses a printhead equipped with a standard nozzle ringed by four additional nozzles. While the standard nozzle deposits material, these additional nozzles add a thin film of different material on top. This allows the interface between each 3D printed line to be controlled and customized in both single- and multi-material printing, eliminating the need for multiple printheads and unnecessary gaps or features in an object.

Beyond creating stronger prints, VI3DP also opens up a range of new applications for 3D-printed objects. In the study, the team demonstrates how they can integrate optical, mechanical, and electrical properties into the interfaces—all in a single print and without increasing weight, time, or cost.
 ..."

From the abstract:
"Interfaces are crucial in natural and engineered systems, dictating essential biological, ecological, and technological properties that augment performance, functionality, and user experience. Yet, achieving precise interfacial control poses significant challenges in both conventional and additive manufacturing, where scalability constraints impede the controlled deposition of quasi-2D layers within 3D objects. This paper introduces Voxel-Interface 3D Printing (VI3DP), which enables comprehensive control over extruded voxel interfaces irrespective of the printhead diameter that conventionally dictates feature size. Various optical, mechanical, and electrical functionalizations, attaining interface thicknesses up to three orders of magnitude smaller than the voxel size are reported. Notable applications include encoding data in soft matter through fluorescent interfaces, creating tight fits and movable mechanisms through non-adhesive interfaces, fabricating bio-inspired composites with tailored failure modes, and developing a single filament capacitive touch sensor. VI3DP opens new avenues for enhanced functionality and efficiency across multiple fields, including biomedical technology, electronics, optics, and nanotechnology."

Turning 3D printing's biggest flaw into its smartest feature | Hub "A Johns Hopkins research team has created a new 3D-printing technique that addresses structural vulnerabilities in 3D-printed objects"

Thursday, August 29, 2024

Sunday, August 25, 2024

World's largest 3D-printed neighborhood with 100 residences nears completion in Texas

Good news! They say everything is bigger in Texas!

"Named Wolf Ranch, the project is located near Austin and is spearheaded by leading 3D-printing firm Icon, with construction firm Lennar, plus high-profile studio Bjarke Ingels Group co-designing. It consists of 100 residences.

The houses are constructed using Icon's Vulcan printer model. It measures 46.6 ft (14.2 m) x 15.6 ft (4.75 m) and can build a house measuring 3,000 sq ft (278 sq m) with minimal human supervision and without needing to be moved around. The giant robotic printer extrudes a proprietary cement-like mixture out of a nozzle in layers, following a blueprint, and builds up the basic shell of the home. ..."

World's largest 3D-printed neighborhood nears completion in USA "An architectural revolution is quietly taking place in the American suburbs. In Texas, a collection of high-tech robotic builders have been busily constructing the largest 3D-printed neighborhood in the world and it's now nearing completion."

Sunday, June 16, 2024

Central Asia's First 3D Printed House Designed to Withstand 7.0 Earthquakes costs about 25,000 Euros and the walls were printed in 5 days

Amazing stuff! I am afraid government regulations in many Western countries would not allow to build such a home. Hopefully, change is coming!

Looks like 3D printed home construction is taking hold in Kazakhstan of all places!

Key points:
"
  • BM Partners [a first of its kind 3D construction printing company in Kazakhstan] completes Central Asia's first 3D printed house in Almaty, Kazakhstan, adhering to strict seismic regulations.
  • Using extra strong concrete normally used for highly loaded structures like skyscrapers and bridges, and other seismic precautions, the house is made to withstand earthquakes of 7 on the Richter scale.
  • The entire building, featuring 100 m2 (1076 SF), was constructed in less than two months, with the walls printed in just five days.
  • To cope with the extreme temperature variations in Kazakhstan the building also contains expanded polystyrene concrete for insulation.
"

"... Marat Oshakhtiev, CEO of BM Partners [founded 2022], shared the vision driving the project: “Embracing modern technologies is essential in today's world. Our company is committed to staying at the forefront of technological advancements with 3D construction printing within our country. With this project, our company has confidently stepped into the future, addressing Kazakhstan’s urgent need for earthquake resistant modernized, efficient and resilient housing solutions“. ..."

Central Asia's First 3D Printed House Designed to Withstand 7.0 Earthquakes






Saturday, June 15, 2024

Researchers demonstrate the first chip-based 3D printer

Amazing stuff! Is there something you can not put on a chip? 😊

"... Imagine a portable 3D printer you could hold in the palm of your hand. The tiny device could enable a user to rapidly create customized, low-cost objects on the go ...
Their proof-of-concept device consists of a single, millimeter-scale photonic chip that emits reconfigurable beams of light into a well of resin that cures into a solid shape when light strikes it.

The prototype chip has no moving parts, instead relying on an array of tiny optical antennas to steer a beam of light. The beam projects up into a liquid resin that has been designed to rapidly cure when exposed to the beam’s wavelength of visible light. ...
In the [future], they envision a system where a photonic chip sits at the bottom of a well of resin and emits a 3D hologram of visible light, rapidly curing an entire object in a single step. ..."

From the abstract:
"Imagine if it were possible to create 3D objects in the palm of your hand within seconds using only a single photonic chip. Although 3D printing has revolutionized the way we create in nearly every aspect of modern society, current 3D printers rely on large and complex mechanical systems to enable layer-by-layer addition of material. This limits print speed, resolution, portability, form factor, and material complexity.
Although there have been recent efforts in developing novel photocuring-based 3D printers that utilize light to transform matter from liquid resins to solid objects using advanced methods, they remain reliant on bulky and complex mechanical systems.
To address these limitations, we combine the fields of silicon photonics and photochemistry to propose the first chip-based 3D printer. The proposed system consists of only a single millimeter-scale photonic chip without any moving parts that emits reconfigurable visible-light holograms up into a simple stationary resin well to enable non-mechanical 3D printing. Furthermore, we experimentally demonstrate a stereolithography-inspired proof-of-concept version of the chip-based 3D printer using a visible-light beam-steering integrated optical phased array and visible-light-curable resin, showing 3D printing using a chip-based system for the first time. This work demonstrates the first steps towards a highly-compact, portable, and low-cost solution for the next generation of 3D printers."

Researchers demonstrate the first chip-based 3D printer | MIT News | Massachusetts Institute of Technology Smaller than a coin, this optical device could enable rapid prototyping on the go.


Fig. 1: The chip-based 3D printer concept.

Fig. 2: The 3D-printer integrated optical phased array architecture