Science of Innovation – a video series – documents how researchers “imagine, invent, improve and inspire” to deliver solutions in health care, energy storage and transportation, to highlight just a few of the sectors mentioned.

Launched in 2012 to celebrate the 165th birthday of Thomas Edison, the videos are produced by NBC Learn in partnership with the National Science Foundation and the United States Patent and Trademark Office.

New episodes
This month, the team has added six more episodes, including clips on the work of Angela Belcher at MIT, and also featuring Adam Feinberg’s group at Carnegie Mellon University.

Belcher’s use of genetically engineered viruses to grow better batteries is the application that often hits the headlines, but her team is also looking at using the technique to improve solar cells, fuel cells, biofuels and cancer therapies. Feinberg is part of the research community applying 3D printing to solve challenges in healthcare, which includes accelerating drug development and advancing personalized medicine.

Device applications for genetically engineered viruses

Overcoming challenges in 3D bioprinting

More videos in the Science of Innovation series
Other topics featured in the new episodes include the microfabrication of cochlear implants; the use of friction stir welding as a tool for tailoring the strength of metallic components; the application of origami structures to enable the transport and easy deployment of large area devices (such as solar arrays); as well as the development of microcontrollers for virtual reality displays.

Read next
– An interview with Gabor Forgacs: from theoretical physics to the business of 3D bio-printing (published in the journal Translational Materials Research)

Open for submissions: TMR focus collection on biomaterials
Guest Editor – Subbu Venkatraman, Nanyang Technological University, Singapore
Since the early days of the artificial hip joint, when metallic, polymeric and even ceramic biomaterials were first implanted as hard-tissue replacements, both natural and synthetic biomaterials have become increasingly important for prolonging as well as improving our quality of life. Building functional body parts from many different material types is now commonplace; transplanting these parts with long-term survivability have become reasonably safe procedures for surgeons. Some of these technologies have progressed so far that the concept of a ‘bionic man’ with several replacement body parts is no longer confined to the world of science fiction [more details].

Related stories
– Virus creates nanoelectrode for battery (nanotechweb.org)

Back in 2013, TMR+ hinted that the arrival of new feedstocks such as TPU 92A-1 – a flexible and durable thermoplastic – would make 3D printers a much more compelling proposition for product developers. Building on this, there are other factors to consider too –

Commercial additive manufacturing (AM) tools with multiple nozzles are paving the way for 3D-printed workpieces with tailored materials properties – the Objet500 Connex3 is a recent example.

In the lab, researchers are exploring AM designs that combine 3D and ink-jet printing, which bring additional functionality through the use of conductive and other custom inks.

3D printers such as the Freeformer from German production tool maker Arburg further extend the choice of starting materials by accepting granulated feedstock rather than specialized spools of pre-formed material that can turn out to be an expensive option for users.

“The mark-up on feedstock for 3D printing can be anywhere from 10 to 100 times the cost of the raw material, so the Arburg tool could be one way around that,” Anthony Vicari of Lux Research told TMR+. “It’s not just about cheaper materials though, there are other benefits,” he added, “you put your material through one less melt cycle, which should reduce product degradation.”

Vicari and his team have recently updated their projections for high-performance thermoplastics and see additive manufacturing as a growth area for this family of materials as 3D printing migrates from prototyping to manufacturing.

Process improvements are also making an impact.

For example, optics specialist LUXeXcel is using a slow curing technique to upgrade the performance of components printed from transparent resins for use in LEDs and other devices. The approach is designed to combat the formation of stepped features that would otherwise occur as a consequence of layer-by-layer fabrication.

Switching from plastics to ceramics, Vicari mentions Ceralink as another example. The US firm has developed a method for producing silicon carbide/silicon carbide composites using powder bed inkjet 3D printers.

The composite material is said to offer lighter weight, higher temperature performance, and higher wear resistance than nickel alloys and titanium alloys for aerospace jet engine components, and this highlights where 3D printing will have the biggest impact – when it brings something different to the process of translating new materials into devices.

Conventional volume manufacturing techniques such as injection molding will always be cheaper on a per unit basis, but this misses the point of 3D printing.

Commercial outlook

3D printing: applications and total addressable market (click on image to enlarge). Source: Lux Research

Some of the unique selling points of AM include customization for market segments such as orthapedic implants, prosthetics and sporting goods. Another positive is product assembly.

“With 3D printing you can often manufacture several parts as one piece, which reduces construction costs, but can also save on regulatory filings too,” Vicari points out.

The on-demand nature of AM means that 3D printing could help firms to reduce product inventory (as well as tooling storage) and lower warehouse costs. It also offers supply-chain security in sectors such as space and defence, by enabling on-site production of replacement parts.

Related links –

TPU 92A-1 datasheet (PDF via materialise.com)

Stratasys’ Big Announcement — Multi-colour, Multi-material 3D Printing with the New Objet500 Connex3 (3dprintingindustry.com)

Printing Batteries – new inks and tools allow 3-D printing of lithium-ion technology (MIT Technology review)

3D Printed Silicon Carbide: Ceralink’s Novel Production Process for Jet Engine Material (luxresearchinc.com/blog)