Supernova Emerges: BCN3D’s VLM Technology Spins Off to Revolutionize Additive Manufacturing with Viscous Resins

In 2022, the additive manufacturing world was abuzz with excitement when BCN3D, a prominent manufacturer known for its innovative IDEX 3D printers, unveiled its groundbreaking Viscous Lithography Manufacturing (VLM) technology. This announcement promised a significant leap forward in resin 3D printing, capable of handling materials previously deemed impossible for such processes. However, after the initial reveal, details surrounding VLM remained scarce, leaving many in the industry anticipating its next move. That silence was broken today with a pivotal press conference from BCN3D, announcing the strategic separation of its VLM division into a brand-new, independent entity named Supernova. This move signals a dedicated push to accelerate the development and market adoption of VLM, ensuring its unique potential is fully realized.

What truly sets VLM apart from conventional resin 3D printing technologies lies in its revolutionary approach to material handling. Unlike established methods such as DLP, SLA, and MSLA, which are limited to low-viscosity resins, VLM is engineered to process highly viscous materials—up to 100 times thicker than those traditionally used. This capability is a game-changer, opening doors to a new realm of material properties and performance. The lithography-based additive manufacturing technique employs a transparent film to precisely transfer these unique resins onto a build platform, where they are then meticulously cured layer by layer. The result? End-use parts boasting superior mechanical properties, durability, and functional performance, drawing comparisons to parts produced via robust methods like powder 3D printing or even injection molding. This ability to bridge the gap between additive and traditional manufacturing processes is a significant advantage, promising a new era for industrial-grade polymer and composite components.

The potential of VLM technology was immediately recognized, creating substantial industry interest. BCN3D reported that over 500 companies have already joined its Technology Adoption Program, eager to explore the capabilities of this cutting-edge process. Furthermore, VLM has fostered ongoing partnerships with leading global brands such as Puma, Saint Gobain, Orbea, Hutchison, and Prodrive, underscoring its broad appeal across diverse sectors. Despite this enthusiastic reception, BCN3D faced a strategic dilemma: balancing the rapid growth and development of VLM with its established IDEX FDM business, which includes flagship products like the Omega i60, first shipped in September 2023. Managing two distinct and complex technologies, each with unique R&D requirements, market strategies, and operational demands, proved challenging. The decision to separate VLM into Supernova was thus a deliberate, forward-thinking move, designed to provide both entities with the dedicated focus and resources necessary to thrive. As BCN3D aptly stated, this separation ensures that “each has its own space to flourish in the long term,” allowing Supernova to pursue its vision for VLM without internal competition for resources and attention, while BCN3D continues to innovate within its core FDM market.

Supernova will be spearheaded by a formidable leadership team, all bringing deep expertise from their previous roles within BCN3D’s VLM division. Roger Antunez, formerly the general manager for VLM at BCN3D, steps into the role of CEO and co-founder of Supernova. His vision and strategic direction will be crucial in guiding the new company. He is joined by Marta Mico, another co-founder, who transitions from VLM Head of Business Development at BCN3D to Head of Business at Supernova. Her experience in market penetration and fostering partnerships will be invaluable. Leading the technological charge will be Eric Pallares, the former CTO of BCN3D, now a Distinguished Technologist at Supernova. Pallares’s profound understanding of the technology and his innovative spirit are set to drive the continuous advancement of VLM. This experienced team ensures Supernova hits the ground running, propelled by individuals who intimately understand the technology and its market potential.

During the press conference, Roger Antunez elaborated on the ambitious aspirations for Supernova. He articulated, “The ambition is to elevate projects through advanced technologies; we want to develop breakthrough new technology and research, pushing the boundaries of what AM has to offer to the world. One of the drawbacks with AM is that the technologies are strong in some ways and weak in others and are often unbalanced because of this. We are lucky at Supernova to be able to work on the innovative VLM process and to further grow with customers.” Antunez’s statement highlights Supernova’s commitment not just to commercialization, but to fundamental innovation. He underscores a critical challenge in additive manufacturing: many existing technologies excel in specific niches but fall short in others, leading to an unbalanced profile. VLM, with its unique material versatility and performance capabilities, aims to address this imbalance, offering a more robust and broadly applicable solution. By fostering close collaboration with customers, Supernova intends to co-develop applications and materials that directly meet industrial demands, pushing VLM to the forefront of manufacturing innovation.

What Can We Expect From Supernova in the Coming Years?

Supernova is strategically positioned with dual headquarters in Austin, Texas, and Barcelona, Spain, reflecting its global ambitions and access to key talent pools. The overarching mission for Supernova is clear: to deliver high-quality parts at scale and at a competitive cost. This objective targets the core pillars of modern manufacturing – achieving excellent results, ensuring high productivity, and maintaining cost-effectiveness with a low cost per part. Over the next year, Antunez affirmed that the company will intensify its focus on refining the VLM technology and expanding its material portfolio in close collaboration with its growing customer base. This customer-centric approach will ensure that developments are directly aligned with industry needs and challenges, guaranteeing practical and impactful solutions.

So, what specific advancements can we anticipate? While Supernova couldn’t provide an exact launch date for its full product offering, Antunez emphasized that significant efforts are currently directed toward developing a comprehensive product ecosystem. The vision is to offer a complete and integrated solution, featuring an automated workflow that minimizes operator interaction and maximizes efficiency. This ecosystem will include a highly advanced, automated washing solution designed to remove uncured resin efficiently. This system will utilize optimized cleaning agents, agitation, ultrasonic technology, and precise heating to ensure thorough and consistent cleaning. Following the washing stage, a crucial post-curing process will be integrated, combining carefully controlled UV light exposure with thermal annealing. This two-pronged approach is essential for achieving the highest possible mechanical performance and material stability in the final parts. Notably, the entire solution – comprising the VLM machine and its integrated post-processing equipment – will be sold as a closed ecosystem, retailing at a price point below $100,000, making advanced industrial additive manufacturing more accessible to a broader range of businesses.

Supernova is also poised to impress with an extensive and innovative material portfolio. Beyond conventional polymers, which include both elastomeric (flexible) and rigid options, the company aims to process silicones and epoxies, significantly broadening the range of applications. Furthermore, the ability to work with advanced materials like ceramics and metals directly within the VLM process positions Supernova at the forefront of material science in additive manufacturing. A particularly exciting feature of VLM is its capacity for multi-material printing. This is a relative rarity among vat photopolymerization methods, typically more common with technologies like material jetting. Multi-material capabilities enable the creation of complex parts with varying properties within a single print, such as rigid structures with flexible hinges or parts combining different colors or functionalities. These advanced material capabilities are expected to be pivotal in pushing VLM technology to new heights and enabling Supernova to target highly demanding and specialized sectors with innovative solutions.

The new company has identified several key target sectors for VLM technology, including defense, space, and transportation. These industries demand parts with extremely high performance, reliability, and specific mechanical properties, making VLM’s ability to process advanced, high-viscosity resins perfectly suited for their stringent requirements. The robust nature of VLM-produced parts, coupled with the ability to work with new material formulations, provides a distinct advantage for creating critical components in these high-stakes environments. Furthermore, Supernova has also highlighted healthcare as a significant potential market. This interest stems from VLM’s unique processing capabilities, which may circumvent some of the persistent biocompatibility challenges observed with traditional resin 3D printing in recent years. The ability to utilize highly viscous, potentially purer, or novel chemical resins could lead to the development of medical devices and implants with improved safety and performance profiles, addressing a critical need within the medical additive manufacturing landscape.

The spin-off of Supernova and the dedicated focus on Viscous Lithography Manufacturing marks a pivotal moment, not just for BCN3D, but for the entire additive manufacturing industry. This strategic move could redefine benchmarks for resin 3D printing, especially concerning material versatility, mechanical performance, and cost-effectiveness. It remains to be seen what the full impact of this announcement will be, but the dedicated resources and experienced leadership at Supernova promise rapid advancements. We eagerly anticipate future developments from Supernova as it continues its expected expansion and innovation throughout 2024. For those interested in learning more, Supernova has launched its official website, which can be accessed HERE. Additionally, the full announcement can be watched in the video below, offering direct insights into the company’s vision and future plans.

What are your thoughts on the announcement of Supernova and the future of Viscous Lithography Manufacturing? What do you believe will be the next major milestones for this innovative company in the additive manufacturing sector? Share your insights and predictions in a comment below, or join the conversation on our LinkedIn, Facebook, and Twitter pages! Don’t miss out on the latest advancements and industry news; sign up for our free weekly newsletter here to receive the most current 3D printing updates directly in your inbox! You can also explore all our engaging videos and exclusive content on our YouTube channel.

*All Photo Credits: Supernova