Archive
Every AppliedAM article, across research, industry, case studies, and insights, in one chronological list.
Why 3D-Printed Ceramics Still Crack
Vat photopolymerization can print ceramic slurries to near-optical resolution, but debinding and sintering remain the steps that decide whether the part survives — and why shrinkage and cracking are still the field's defining problem.
Three Ways to Build in Metal
Laser powder bed fusion, directed energy deposition, and binder jetting reach full density through fundamentally different physics, each trading resolution, build rate, and cost differently.
Lattices That Design Themselves
Topology optimization and lattice infill are converging with additive manufacturing's own physical constraints, so that overhang angles and minimum feature size are now part of the mathematics that generates a part's shape, not an afterthought.
Why Two CT Scans of the Same AM Part Can Disagree: Porosity Metrology and the Partial-Volume Effect
X-ray computed tomography has replaced destructive sectioning as the primary way to inspect internal porosity in metal additive manufacturing, but its porosity numbers are only meaningful alongside the resolution and threshold used to produce them.
Support Structures in Additive Manufacturing: Thermomechanical Origins and Design Mitigation Strategies
Support structures are not a slicer-stage afterthought. Their necessity, geometry, and cost are governed by distinct thermal and kinetic mechanisms in powder bed fusion, material extrusion, and vat photopolymerization.
Where Additive Manufacturing Is Actually Winning Right Now
Past the hype cycle: the specific applications where AM has moved from demo to dependable production, and where it still falls short.
Post-Processing for FDM and SLA: What Each Method Actually Does
Sanding, vapor smoothing, curing, painting - what each technique changes, and when it is worth the time.
Slicer Settings That Actually Matter
Your slicer has 200+ parameters. These are the handful that actually change how your part performs.
The Bimetallic Problem Almost Nobody Is Printing
Grad student and AM professional Ayman Ahdy is using rare access to wire laser metal deposition equipment to study bimetallic printing, joining mild steel and stainless steel for cheaper, corrosion-resistant marine parts.
Design for Additive Manufacturing: What Actually Changes When You Print
DfAM is not about avoiding print failures. It is about making decisions upstream - orientation, overhangs, wall thickness, support strategy - before the slicer is ever opened.
Where to Actually Find Free 3D Models Worth Printing
Not all free model repositories are built for AM practitioners. Here is where to look - and what to watch out for.
A $200,000 Problem - and a Student at Western University, Canada, Who Is 3D Printing the Solution
Graduate student Rebecca Kaaya Nansubuga is developing an open-source 3D-printed orthopedic surgical positioning table, bringing a $200,000 piece of operating room equipment within reach of any facility with a desktop printer.
Empowering the Next Generation: 3D Printing, Robotics, and the Future of Education
How a zombie-themed 3D printing workshop in Sri Lanka sparked creativity and problem-solving in kids, and what it means for the future of technology education.
Jerk, Junction Deviation and Real Jerk (Cheetah): Smarter Motion in 3D Printing
From classic jerk control to dynamic junction deviation and UltiMaker's Cheetah motion planner, here is how smarter motion control is transforming 3D print quality and speed.
3D Scanning and 3D Printing: From Point Cloud to Physical Object
A practical guide to 3D scanning technologies, from photo capture and photobooth scanners to structured light, laser, and infrared systems, and how they feed into real-world 3D printing workflows.
Is 3D Printing Really Changing the Production Space?
How a custom 3D-printed jig solved a UV printing bottleneck for embossing logos on 10,000 glass tubes, cutting per-batch production time from 20 minutes to just a few seconds.
Polymer Additive Manufacturing: Beyond the Standard Classification
If you can only name a handful of polymer 3D printing techniques, it is time to expand your knowledge. AMPOWER has mapped over 16 distinct polymer AM processes, far beyond the seven categories in the ASTM/ISO 52900 standard.
Metal FFF and Catalytic Debinding: What Every Practitioner Should Know
Metal Fused Filament Fabrication is a three-stage process of printing, debinding, and sintering. This article breaks down catalytic debinding, the fastest and most widely adopted method, and explains why filament composition is critical to getting it right.
Lightweight Drone Frame Using Topology-Optimized FDM Parts
A student project using topology optimization and FDM to build a drone frame 40% lighter than a standard design.
FDM 3D Printing: A Complete Guide for Engineers
A comprehensive guide to Fused Deposition Modeling, how it works, material choices, print settings, and real-world applications.