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الوسم: 3D Printing

  • Innovative 3D Printing Technique Promises New Era in Reactor Production


    A hybrid manufacturing process merges 3D printing, electroforming, and hot isostatic pressing to produce key components for advanced nuclear reactors and other energy and defense systems. Credit: Morgan Manning, Brett Hopwood/ORNL.

    Researchers at Oak Ridge National Laboratory (ORNL) in partnership with A.J. Tuck Company have introduced a new manufacturing method that could streamline the production of vital parts for next-generation nuclear reactors.

    This innovative process combines additive manufacturing with electroforming to create intricate, leak-proof containers known as hot isostatic pressing (HIP) cans.

    These containers are essential for producing durable metal components from powdered raw materials under extremely high heat and pressure conditions.

    The development aims to overcome a significant hurdle in the U.S. nuclear industry: the limited ability to produce large, complex metal parts domestically.

    Traditional methods like forging and casting demand large, specialized facilities, costly equipment, and lengthy lead times. Much of this manufacturing infrastructure has shifted overseas.

    The new method offers a more straightforward alternative.

    It starts with 3D printing a plastic (polymer) mold shaped precisely like the finished part. Since plastic is easier and cheaper to shape than metal at high temperatures, designs can be produced quickly and with less expense.

    Next, the polymer mold is submerged in a liquid chemical bath. Using electrical current, electroforming deposits a dense layer of nickel onto the surface, resulting in a highly accurate metal shell approximately 2 to 3 millimeters thick.

    Once the nickel layer is formed, the plastic mold is removed, leaving behind a hollow nickel container. This shell can then be filled with metal powder, sealed, and subjected to the HIP process. Under high heat and pressure, the powder fuses into a solid metal part.

    This approach offers several benefits. Manufacturing the initial form from polymer avoids some distortions and stresses that are common when directly 3D-printing metal components at extremely high temperatures. It also lowers costs and simplifies design modifications.

    Electroforming allows for detailed and precise shapes and can be scaled up with relative ease. According to ORNL mechanical engineer Amiee Jackson, the time required largely depends on the thickness of the metal coating rather than the size of the component. Multiple parts could potentially be produced simultaneously.

    In early testing, researchers successfully created five leak-proof cylindrical HIP cans, each about 15 centimeters tall and 10 centimeters in diameter. They also designed an integrated port that eliminates the need for separate welds of process tubes—a common failure point in traditional manufacturing.

    Currently, efforts are underway to test more complex shapes, such as impellers used in pumps and turbines, and valves relevant to nuclear systems.

    This technology’s applications extend beyond HIP cans. It has the potential to produce large, precise components for reactor pressure vessels, valves, turbines, and other energy system parts.

    With growing interest in advanced and small modular nuclear reactors, rapid and flexible manufacturing methods like this could become increasingly vital. They may enhance domestic production capabilities and reduce reliance on overseas supply chains.

    An invention disclosure and provisional patent application have already been submitted for this innovative manufacturing approach.

  • Easy Heat Treatment Boosts Durability of 3D-Printed Metal Parts for Rockets & EVs

    Easy Heat Treatment Boosts Durability of 3D-Printed Metal Parts for Rockets & EVs

    Credit: NASA


    Scientists have discovered a method to enhance the performance of 3D-printed aluminum bronze, a metal that could be useful for cooling high-powered electronic components in rockets, airplanes, and electric vehicles.

    Researchers from Skoltech and the State Marine Technical University investigated how different heat treatments influence aluminum bronze produced through 3D printing.

    They found that heating the printed metal to specific temperatures can create an improved balance between strength and flexibility—the capacity of a material to bend or stretch without breaking.

    The results were published in the Journal of Alloys and Compounds.

    Modern electronics generate significant amounts of heat, especially powerful processors and other high-demand components.

    Heat exchangers help transfer this heat away, preventing overheating of sensitive electronics.

    The material used for these cooling systems must be an effective conductor of heat while maintaining mechanical strength, which is especially critical in rockets, airplanes, and electric cars, where components face vibrations, shocks, and repeated temperature and stress changes.

    While copper might seem like the obvious choice due to its excellent thermal conductivity, it poses challenges for 3D printing with infrared lasers. Copper’s high thermal conductivity rapidly disperses heat during the printing process, and its reflective surface makes laser energy absorption difficult. Additionally, pure copper is relatively soft, allowing thin structures to deform under mechanical loads.

    Aluminum bronze, an alloy with about 10% aluminum and 1% iron mixed with copper, offers a feasible alternative. It’s easier to print and mechanically stronger than pure copper, though with lower thermal conductivity.

    However, 3D printing introduces another challenge. Metals tend to cool and solidify very quickly during printing, which can lead to uneven chemical compositions and unstable microscopic structures. These tiny variations can influence the final strength and flexibility of the component.

    After examining the internal structure of 3D-printed aluminum bronze with a scanning electron microscope, the scientists hypothesized that post-print heat treatment could improve its internal organization.

    They subjected samples to an electric furnace at three different temperatures—300°C, 400°C, and 500°C—for three hours each. The samples were then tested and compared to untreated aluminum bronze.

    Temperature proved to be a key factor.

    Heating to 300°C or 400°C actually degraded the material’s properties. These temperatures promoted the formation of unstable phases within the alloy, reducing its ductility and increasing brittleness.

    In contrast, heating to 500°C brought about significantly different results. At this higher temperature, atoms could move and repopulate the alloy more effectively, smoothing out chemical irregularities and stabilizing the microscopic structure. The outcome was a much better compromise between strength and flexibility.

    The researchers emphasize that this study demonstrates why standard heat treatments used for traditionally manufactured metals cannot be directly applied to 3D-printed materials without thorough testing.

    The next step involves assessing whether heating aluminum bronze to 500°C compromises its heat-conducting abilities. If it retains good thermal conductivity, this approach could offer a practical method for manufacturing durable, complex cooling components for high-performance electronics in electric vehicles, aircraft, rockets, and other advanced technologies.

  • Deep-Sea Sponge Designs Lightweight, Durable Materials Resistant to Vibrations

    Deep-Sea Sponge Designs Lightweight, Durable Materials Resistant to Vibrations

    A remarkable deep-sea sponge has inspired researchers to create a new class of lightweight materials that are not only stronger but also more efficient at handling flowing air or water. This innovation could enhance aircraft components, underwater structures, and even medical devices.

    Scientists from the University of California, Berkeley, and Harvard University based their research on the Venus’ flower basket, a glass sponge thriving more than 500 meters below the ocean surface. Despite its fragile appearance, this sponge boasts an incredibly durable yet lightweight skeleton—a feature that has intrigued researchers for nearly 200 years.

    Published in Nature Communications, the team’s study introduces a computer-driven design system that enables engineers to craft materials balancing two key qualities: mechanical strength and optimal fluid flow. Achieving both simultaneously has traditionally been difficult; structures designed for high strength often cause turbulence, while designs optimized for fluid movement can compromise structural integrity. The team aimed to tackle both issues at once.

    The Venus’ flower basket provided an ideal model. Its intricate silica framework withstands the immense pressure and strong currents of deep oceans for centuries. Simultaneously, its lattice-like structure smoothly guides water through and around the sponge, aiding in food collection while minimizing stress from ocean currents.

    Inspired by this natural architecture, the researchers developed an automated computer framework combining mechanical engineering principles with advanced fluid dynamics simulations. Users input desired performance criteria, and the system evaluates hundreds of potential designs, iteratively refining them to find the optimal balance between strength and fluid efficiency.

    The software integrates two established engineering techniques: Finite Element Analysis, which predicts how structures respond to forces, and Computational Fluid Dynamics, which simulates how fluids move around objects. By merging these methods, the framework can optimize materials in ways previously deemed difficult.

    Once the optimal designs were generated digitally, the team 3D printed physical samples and tested their strength and fluid behavior. The experiments confirmed that the computer models aligned well with real-world results. The specially designed materials could withstand roughly 140% more load before buckling compared to randomly designed counterparts, without using extra material.

    Additionally, introducing just about 5% open space within the structure significantly reduced vortex shedding—a phenomenon where swirling vortices form behind objects flowing in air or water—causing repetitive forces that induce vibrations and fatigue over time. Carefully shaping the internal layout allowed fluids to flow more smoothly, decreasing vibrations and further increasing durability.

    The researchers believe this optimization framework can be adapted to develop advanced materials across various fields. Possible applications include underwater pipelines, offshore installations, aircraft wings, helicopter parts, and medical stents designed to improve blood and fluid flow.

    This work demonstrates how millions of years of natural evolution, exemplified by the Venus’ flower basket, can inform modern engineering solutions. By studying one of the ocean’s most extraordinary creatures, scientists have shown that smarter, more resilient materials can be crafted through better design—often with less material—rather than relying solely on increased volume or strength.

    The full study appears in Nature Communications, supported by findings from UC Berkeley.

  • Ice Cream Ingredient May Transform Soil into 3D-Printed Homes

    Ice Cream Ingredient May Transform Soil into 3D-Printed Homes

    A common ingredient in ice cream might hold the key to transforming everyday dirt into eco-friendly building materials. Researchers at the University of Colorado Boulder have found that sodium alginate, a substance derived from seaweed and commonly used to improve food texture, can make natural materials like clay and sand much easier to 3D print into durable structures. This breakthrough could potentially cut down on construction waste and reduce the environmental footprint of building projects.

    Humans have utilized earth as a primary building material for thousands of years. Traditional structures such as adobe homes were crafted from clay, sand, and other natural elements. Many animals also use earth-based construction: termites build towering mounds, wasps create complex nests, and honeycomb worms form reef-like structures along coastlines. These creatures don’t rely on cement; instead, they depend on natural biopolymers—substances acting like glue—to bind soil particles together.

    Inspired by these natural architects, the research team wanted to discover which biopolymers could help turn soil into a suitable material for modern 3D printing. They tested five food-grade biopolymers. Some are already used in products like salad dressings to prevent ingredients from separating, while others come from seaweed or are produced through sugar fermentation.

    One of these substances, locust bean gum, tightly bonded soil particles, creating a strong material. However, it also made the mixture too thick and difficult to extrude through a 3D printer. Sodium alginate, on the other hand, behaved differently. Instead of acting like glue, it altered the electrical charges on clay particles, causing them to repel each other—similar to like poles of magnets pushing apart.

    This charge-based effect allowed soil particles to stay evenly suspended in the mixture while flowing smoothly through the printer nozzle. The result was a material that could be printed quickly and more easily. Remarkably, only a tiny amount of sodium alginate—about 0.12%—was necessary. When added to soil from a Colorado granite quarry, the mixture became both stronger and more printable. It could withstand roughly 25% more pressure than untreated soil and was about 33% faster to print.

    Using this new formulation, the team crafted a thin wall only 8 millimeters thick that remained stable even when tilted at a 60-degree angle—steeper than the Leaning Tower of Pisa. The researchers highlight that earthen building materials offer additional advantages: earth naturally helps regulate indoor humidity, absorbs some pollutants from the air, and provides insulation, keeping buildings cooler in summer and warmer in winter.

    Moreover, construction projects often produce large amounts of excavated soil while digging foundations, basements, or parking lots, much of which ends up in landfills. The new approach could enable builders to reuse soil directly on-site, reducing waste and promoting sustainability. Since clay and sand are among the most plentiful natural resources, this seaweed-derived additive could pave the way for more sustainable, environmentally friendly construction worldwide.

  • Trump open to reviewing Iran sanction removal

    Trump open to reviewing Iran sanction removal

    A 3D-printed miniature figure of Donald Trump accompanied by the flags of the United States and Iran can be seen in this image taken on January 15, 2025. — Reuters

    – Western nations accuse Iran of attempting to develop nuclear weapons.
    – Iran asserts its nuclear activities are solely for peaceful energy purposes.
    – Sanctions are imposed to restrict Iran’s nuclear and missile-related dealings.

    Washington: President Donald Trump announced Thursday that Iran has requested the lifting of hefty U.S. sanctions on Tehran and expressed willingness to discuss the matter.

    “Honestly, Iran has been asking if the sanctions could be lifted. They’re under very severe U.S. sanctions, which makes things challenging,” Trump stated during a dinner with Central Asian leaders.

    “I’m willing to listen and see what might happen, but I am open to that possibility.”

    For years, Western countries, including the United States, have accused Iran of pursuing atomic weapons, a claim Iran denies by stating its nuclear program is for peaceful energy development.

    Iran has been under international sanctions for several years, especially after the U.S. withdrew from the 2015 nuclear deal with Iran in 2018 and reinstated strict punitive measures.

    In June, Israel conducted an unprecedented bombing campaign against Iran, which led to a brief war involving U.S. military strikes on Iranian nuclear facilities.

    That 12-day conflict with Israel, which included missile and drone attacks from Iran, disrupted nuclear negotiations between Tehran and Washington that had started in April.

    Trump claimed that Iran was once the “bully of the Middle East” but no longer possesses the “possibility of nuclear weapons.”

    Since regaining office in January, Trump has repeatedly stated that the strikes destroyed Iran’s nuclear capabilities, although the full extent of the damage remains unclear.

    In September, the UN reimposed sanctions on Tehran under the “snapback” mechanism initiated by Britain, France, and Germany. These measures restrict dealings related to Iran’s nuclear and missile programs.

    Oman, which has hosted several rounds of U.S.-Iran nuclear talks, has urged both sides to resume negotiations aimed at a new deal that would limit Iran’s nuclear activities in exchange for sanctions relief.

  • Dubai Greenlights First 3D Printed Building

    Dubai Greenlights First 3D Printed Building

    Dubai’s Planning and Development Department – Trakhees has granted approval for the city’s first building to be constructed using 3D printing technology. The pioneering project, part of Nakheel’s Al Furjan Hills development, has swiftly progressed from licensing to completion in a mere 20 days.

    The milestone for the construction industry in Dubai was made possible following the issuance of Decree No.24 by Sheikh Mohammed Bin Rashid Al Maktoum, UAE Prime Minister and Ruler of Dubai, in 2021. This decree set the regulatory framework for incorporating 3D printing in construction practices, emphasizing the emirate’s commitment to fostering innovation, sustainability, and urban advancement.

    “Spearheading economic growth, environmental stewardship, and urban development in Dubai through innovative solutions is our mission with the implementation of this Decree,” stated Sultan Ahmed Bin Sulayem, Chairman of the Ports, Customs, and Free Zone Corporation. He highlighted the collaborative efforts of Trakhees and key stakeholders in realizing the project, underscoring its significance in promoting cutting-edge technology and knowledge-based economic initiatives in line with the D33 vision.

    Bin Sulayem emphasized Trakhees’ dedication to facilitating licensing procedures and ensuring regulatory adherence within PCFC’s jurisdiction to support Dubai’s ambitious goal of having 25 percent of buildings constructed using 3D printing by 2030.

    Discussing the environmental advantages of 3D printing technology over conventional methods, Bin Sulayem noted, “3D printing stands out as a sustainable construction approach, with a robotic arm directly depositing layers of cement-based material onto a prepared surface, eliminating the need for concrete pouring.”

    Abdullah Belhoul, CEO of the Department of Planning and Development at Trakhees, PCFC, highlighted how the approval of Dubai’s first 3D printed building opens new possibilities for architectural engineering in the city, bolstering the local economy and demonstrating a commitment to embracing innovative and eco-friendly construction practices.