Revolution in 3D printing: setting new standards for the industry!

Revolution in 3D printing: setting new standards for the industry!

On August 20, 2025, researchers at the University of Duisburg-Essen will provide information about groundbreaking advances in the field of 3D printing, in particular through the laser powder bed fusion (LPBF) process. How uni-due.de reports, LPBF has established itself as a widespread industrial 3D printing process that is particularly used in the aerospace, medical technology and tool making sectors. These technologies enable the production of complex and highly resilient components.

Research was carried out over a period of six years as part of a priority program funded by the German Research Foundation (DFG) entitled “Materials for Additive Manufacturing”. This program has now been successfully completed and the knowledge gained has been made available via an interlaboratory study and a special issue of the journal Advanced Engineering Materials. Dr. Anna Ziefuß, one of the researchers involved, describes the results of the interlaboratory study as a milestone for science and industry.

Standardization and research results

The interlaboratory study, considered the largest open data set of its kind, involved the collaboration of 32 international laboratories. The aim was to promote the standardized production of components from metallic and polymer powders. In particular, the comparison of material properties, machine parameters and process management was examined.

A central goal of these research efforts is the improvement and standardization of materials and additive processes. The priority program SPP 2122 was launched in 2019, involving over 30 research teams in the development of tailor-made powders and the functionalization of nanoparticles. From November 10, 2025, the data collected from the interlaboratory study will be publicly available.

In addition to LPBF, additive manufacturing relies on various other processes such as fused filament fabrication (FFF) and robocasting. According to information from iwn.fraunhofer.de fluid rheology significantly influences the pressure behavior during material extrusion. A mixture of polymer filaments and high-melting particles is used, which are melted and processed through a nozzle.

In projects, data collection is also supported by numerical simulations to make various aspects of the printing process more efficient. These are important steps in identifying ideal paste compositions required for the desired printed objects.

The context of 3D printing

3D printing, also known as additive manufacturing, describes processes for producing three-dimensional objects by applying material layer by layer. This process has developed rapidly since the 1980s and is used in a variety of areas, including industry, research, construction and medical technology. Materials are processed under computer control based on CAD/CAM data, which increases cost-effectiveness as the number of pieces decreases and geometric complexity increases.

However, the challenges of 3D printing technologies are diverse. These include legal aspects, health risks and material costs. Although training and further education in additive manufacturing are diverse, there is no specific training occupation in this area. How Wikipedia makes it clear, 3D printing not only opens up new production possibilities, but also innovative approaches in research, such as bioprinting for the production of organs and tissues.

In summary, 3D printing is at a turning point where standardization and improvement of processes are crucial for the further development of new materials and technical applications. The results of ongoing research projects promise to have far-reaching impacts on the industry.