By Andreas Wagner, Helen Rogers, and Alina Le
Additive Manufacturing (AM) technologies have transformed the manufacturing industry by offering increased agility, lot size flexibility, and improved design freedom. AM has become an alternative to traditional manufacturing technologies, particularly for niche, customized, and one-of-a-kind products. It is highly valued due to the vast design freedom and optimization possibilities it offers and provides almost unlimited potential for improving the design and properties of components. Although these advancements have led to new business models such as 3D-printing-as-a-service and AM marketplaces, AM adoption has been slower than expected. This is due to a combination of process factors, such as competing against well-established traditional manufacturing supply chains (including CNC machining, injection molding, and forming), and technical factors, such as AM’s scale-up and reliability limitations. Ongoing research has enabled the technology to leap forward from single- to multi-material additive manufacturing (MMAM). This facilitates the integration of multiple materials into a single object and paves the way for significant advances in design, performance, and functionality. However, three factors are critical when selecting a manufacturing process for a particular application: feasibility, cost-effectiveness, and speed, as shown in Figure 1.
Figure 1: MMAM Applications
As many industries demand ever more complex and innovative components, MMAM is leading the way in next-generation prototyping and exploring novel structures. Current industrial use cases for MMAM are typically limited to high-tech scenarios:
- The aerospace industry requires lightweight, high strength, aerodynamics, and system efficiency. MMAM offers significant advantages by enabling the creation of complex geometries and optimized material properties, which are crucial for enhancing system efficiency, reducing weight and cost, and improving performance in both aviation and space applications. Showcase: multi-material combustion chamber
- The automation industry demands advanced solutions to accommodate high volumes and complex structures. MMAM is pivotal in optimizing automation engineering by enabling the creation of compact, multifunctional components, especially for robotics. MMAM’s ability to integrate multiple materials allows for the development of biomimetic designs and soft robotics, which improve efficiency and flexibility in handling key tasks and enhancing automation systems. Showcase: biomimetic soft gripper
- Industrial manufacturing requires advanced technologies such as machining, injection molding, and forming to produce single parts up to large quantities. Although MMAM has significant potential here, it is unlikely to replace traditional manufacturing due to cost and time factors completely. However, the MMAM value chain fits into and complements the value chain of traditional manufacturing processes, for example, by producing parts that improve tool properties, increase cooling efficiency, and increase overall manufacturing productivity. Showcase: multi-material heat sink
- The biomedical industry faces a critical need for advanced solutions to address organ and tissue shortages. MMAM offers significant potential by enabling the precise creation of complex biomimetic designs, which are essential for producing medical models, tissues, and organs. MMAM facilitates the production of detailed 3D models and bioprinting components such as heart valves, bones, and tissues. Advancements in sensor monitored implants and drug delivery systems achieved with MMAM are promoting tailored and effective biomedical applications. Showcase: smart hip implant
Overall, MMAM is highlighted in these industries as an innovative technology, for designing components with complex geometries and tailormade material design requirements. Despite its transformative potential, MMAM faces challenges. In particular, high energy consumption (and hence costs) and the urgent need for improved recycling practices are major hurdles. MMAM’s high manufacturing costs make it difficult to justify business cases, especially if a product can be efficiently produced using existing manufacturing technologies. As research continues, solutions will be found, meaning wider industrial adoption of MMAM is likely.
Digging Deeper:
A. Wagner, H. Rogers and A. Le, ‘Exploring New Frontiers in Multi-Material Additive Manufacturing,’ in IEEE Engineering Management Review, doi: 10.1109/EMR.2024.3412403.
A. Bandyopadhyay and B. Heer, ‘Additive manufacturing of multi-material structures’, Mater. Sci. Eng. R Rep., vol. 129, pp. 1–16, Jul. 2018, doi: 10.1016/j.mser.2018.04.001 .
H. Rogers, N. Baricz, and K. S. Pawar, ‘3D printing services: classification, supply chain implications and research agenda’, Int. J. Phys. Distrib. Logist. Manag., vol. 46, no. 10, pp. 886–907, Nov. 2016, doi: 10.1108/IJPDLM-07-2016-0210 .
About the Authors
Andreas Wagner completed his education in Industrial Engineering at the Technische Hochschule Nürnberg/ Ohm University, Germany. Andreas also serves as a partner at Wagner MKT OHG in Ingolstadt, Germany, specializing in high-precision CNC machining and post-processing methods. You can reach him via email
Helen Rogers (Member, IEEE), is a Business Research Professor specializing in Sustainable Business Models for Emerging Technologies at the Technische Hochschule Nürnberg / Ohm University, Germany. You can contact her via email.
Alina Le is a Research Assistant at the Faculty of Business Administration at the Technische Hochschule Nürnberg /Ohm University, Germany. You can contact her via LinkedIn.
