Researchers at the École Polytechnique Fédérale de Lausanne (EPFL) have developed a 3D printing method that creates materials capable of withstanding 20 times more pressure than traditional printed structures. This innovation could transform the production of metals and ceramics for aerospace, robotics, and medical applications.
A New Way to Build Strength
Conventional 3D printing often leads to shrinkage, porosity, and warping. EPFL’s team solved this by printing a hydrogel scaffold, a water-based gel serving as a blank framework. They infused the gel with metal salts, which react to form nanoparticles. Repeating this process builds dense metal or ceramic structures. Heating removes the gel, leaving a strong, lightweight framework.
This “grow-inside” approach allows the metal to form naturally within the printed design, reducing defects and shrinkage from 90% to around 20%. The result is materials that are both stronger and more durable.
Stronger, Lighter, and More Versatile
Tests on gyroid lattices made of iron, copper, and silver showed these structures can endure pressures 20 times higher than older methods. The combination of strength and low weight makes the technique ideal for precise, resilient components.
Toward the Future of Manufacturing
By merging chemistry, materials science, and engineering, EPFL researchers have expanded the limits of 3D printing. Their innovation paves the way for next-generation materials that are stronger, adaptable, and ready for demanding environments.
