Carbon 3D Printing at RAPID + TCT: Redefining Manufacturing with Advanced DLS Technology and End-to-End Solutions

For anyone deeply immersed in the world of advanced manufacturing and additive technologies, the name Carbon is undoubtedly familiar. This pioneering company has carved out a significant niche for itself, primarily through its groundbreaking Digital Light Synthesis (DLS) process. This innovative approach to resin 3D printing introduces a unique “pocket of air” – an oxygen-permeable window – that allows for continuous liquid interface production, leading to unprecedented printing speeds and unparalleled ease of operation. This technological leap has opened doors to some truly remarkable applications, perhaps most notably exemplified by its collaboration with adidas to produce high-performance 3D printed footwear components at scale. Yet, Carbon’s journey of innovation is far from over. The company consistently pushes the boundaries of what’s possible in additive manufacturing, and this relentless pursuit of advancement is precisely what Carbon aims to highlight at this year’s RAPID + TCT event. We had the privilege of speaking with Gary Miller, a key figure at Carbon, to delve deeper into their latest developments and vision for the future.

3DN: Could you introduce yourself and your role at Carbon?

Certainly. My name is Gary Miller, and I serve as one of the Production Success Managers at Carbon. My role involves ensuring that our customers not only adopt our additive manufacturing solutions effectively but also achieve tangible, measurable success in their production workflows. This often means working closely with them to optimize processes, leverage our technology to its fullest potential, and troubleshoot any challenges that may arise. My professional journey in this industry spans nearly two decades; prior to joining Carbon, I operated my own service bureau for 18 years, during which I gained extensive hands-on experience with a wide array of additive technologies. This background has given me a deep understanding of the diverse needs and operational complexities faced by companies looking to integrate 3D printing into their manufacturing strategies, from prototyping to full-scale production. This practical experience is invaluable in helping our Carbon customers navigate their own additive manufacturing transformations and achieve their strategic objectives.

3DN: What exciting innovations is Carbon showcasing at RAPID + TCT this year?

This year, our primary focus at RAPID + TCT is to spotlight our comprehensive portfolio of engineering-grade materials. These advanced materials are specifically designed to empower our customers to seamlessly transition from initial product prototyping directly into full-scale production, all within the same unified platform. This capability is a game-changer for many industries, as it dramatically reduces product development cycles and significantly cuts down on traditional tooling costs, which can be a major barrier to innovation. By enabling this seamless transition, we allow our customers to not only develop superior products with enhanced functionalities but also to bring these innovative solutions to market much faster than ever before. We are incredibly enthusiastic about sharing some of the most recent and impactful applications that have been brought to life using our best-in-class industrial printers. These applications span various sectors, demonstrating the versatility and robust performance of our DLS technology and advanced materials in real-world scenarios. We eagerly anticipate engaging with visitors at the show, understanding their unique product development needs, and showcasing how our integrated platform – a synergistic combination of cutting-edge hardware, intuitive software, and high-performance materials – can unlock new possibilities and meet their specific production requirements. We believe this holistic approach is key to driving the future of digital manufacturing.

Our engineering-grade materials represent a critical component of our ecosystem, offering properties that rival or even surpass those of traditionally manufactured parts. These materials are rigorously tested and validated for demanding applications, ensuring durability, temperature resistance, flexibility, and other critical performance attributes necessary for end-use products. This emphasis on material science underscores our commitment to providing not just a printing solution, but a comprehensive manufacturing capability that addresses the intricate needs of modern product design and engineering. From robust, impact-resistant polymers for automotive components to biocompatible resins for medical devices, our material library is continuously expanding to support an ever-growing range of industrial applications. This allows customers to leverage the speed and design freedom of additive manufacturing without compromising on the quality or performance required for mass production.

3DN: What are your expectations for the show, and what aspects are you most excited about?

My expectations for RAPID + TCT are always high, and this year is no exception. I anticipate witnessing an impressive display of the very latest and greatest 3D printing and additive manufacturing solutions from across the industry. Even though Formnext in Germany, another major industry event, concluded just five months ago, the pace of advancements in Carbon’s world, and indeed in the broader additive manufacturing landscape, never truly slows down. There is a constant, dynamic evolution occurring, ranging from breakthroughs in new material developments that unlock entirely new application possibilities to cutting-edge software upgrades that enhance design capabilities, streamline workflows, and improve overall operational efficiency. There is always something new and exciting on the horizon for those of us deeply involved in this field.

This event, RAPID + TCT, promises an exciting array of fresh introductions and significant technological advancements, not only from Carbon but also from many other key players and innovators within the industry. Beyond the tangible innovations and product showcases, these gatherings also offer an incredibly valuable opportunity for vital networking and collaboration. It’s a chance to reconnect with familiar faces, fostering stronger industry relationships, and cultivating new partnerships that can drive future advancements. There’s an undeniable shared enthusiasm for the future of additive manufacturing that permeates these events, and being a part of that collective energy is always incredibly invigorating. It’s where ideas are exchanged, challenges are discussed, and the next generation of manufacturing solutions begins to take shape. I am particularly excited to see how the industry is collectively moving towards more sustainable, efficient, and integrated manufacturing processes, and how Carbon’s contributions fit into that larger picture. The synergy created by bringing together engineers, designers, material scientists, and business leaders under one roof is truly unparalleled and is a major highlight of any major AM exhibition.

3DN: What is a common misconception, either about your products specifically or additive manufacturing in general?

One of the most pervasive misconceptions, both about advanced additive manufacturing solutions like Carbon’s and about the broader AM industry, is the belief that the 3D printer itself is the “be-all and end-all.” While the physical printing hardware is undoubtedly a crucial component, from our perspective at Carbon, it represents only one part of a much larger, interconnected system. What truly enables us to solve complex engineering challenges and empower creators to develop superior products and bring them to market faster is the complete ecosystem: the seamless integration of sophisticated hardware, intelligent software, and advanced, application-specific materials. This synergistic relationship is what drives real innovation and unlocks the full potential of digital manufacturing.

At Carbon, one of our greatest strengths lies in our vertically integrated teams. These teams, encompassing everything from material scientists and software engineers to hardware developers and application specialists, work together in an exceptionally tight-knit and collaborative manner. This integration ensures that every component of our ecosystem is optimized to work in perfect harmony, leading to unparalleled performance, reliability, and ease of use for our customers. It allows for rapid iteration and innovation across the entire platform, rather than in isolated silos.

To that end, a significant part of our mission is to inspire and educate the design engineering community about what is truly achievable with this integrated approach. We find that this group, the designers and engineers at the forefront of product creation, are often less concerned with the intricate technical specifications of the machine they are using to build a product. Their primary focus, and rightly so, is on the performance specifications, functional attributes, and aesthetic qualities of the final product they are striving to build. By providing a holistic solution that optimizes for these final product characteristics – enabling complex geometries, lightweighting, functional integration, and accelerated design cycles – we empower engineers to transcend traditional manufacturing constraints and bring truly revolutionary products to life. We encourage them to think beyond traditional limitations, fostering creativity and pushing the boundaries of what was previously considered impossible in product design and development. This ecosystem approach is what truly differentiates Carbon in the additive manufacturing space, offering not just a tool, but a complete solution for innovation.

3DN: What message would you share with attendees to invite them to RAPID + TCT and encourage them to stop by the Carbon booth?

To all prospective attendees of RAPID + TCT, I would emphasize a fundamental truth about manufacturing today: simply sticking with traditional product manufacturing methods will, by its very nature, only ever deliver traditional levels of benefits and incremental improvements. In an increasingly competitive and rapidly evolving global market, relying solely on conventional approaches risks stagnation. This event, however, unlocks a door into a completely new paradigm – a completely new way of doing things, of designing, producing, and bringing innovative products to market. It’s an opportunity to explore the transformative power of digital manufacturing and see firsthand how it can redefine your business.

We extend a warm and enthusiastic invitation to everyone to visit the Carbon team at booth #2848. When you stop by, we won’t just showcase our technology; we’ll engage with you in a meaningful conversation. We are eager to “walk through the door with you,” metaphorically speaking, to deeply understand your specific business objectives, your current manufacturing challenges, and your aspirations for product innovation. Our goal is not just to sell you a machine, but to partner with you. We want to help you fundamentally transform the way you design and make products, enabling them to deliver the enhanced performance, superior comfort, and critical protection that today’s discerning markets and demanding applications require. Whether you’re looking to achieve lighter components, more intricate designs, accelerated product cycles, or entirely new functionalities, the Carbon team is equipped with the expertise and the integrated solutions – hardware, software, and materials – to guide you through this journey. Come and discover how additive manufacturing can become a cornerstone of your competitive advantage and a catalyst for future growth.

3DN: Do you have any final words or advice for our audience navigating the show?

Absolutely. For all attendees making their way through the bustling halls of RAPID + TCT, I offer a few pieces of advice to maximize your experience. First, “drink up the show” – immerse yourself fully in the vast array of innovations, ideas, and expertise on display. Take the time to speak to those exhibitors who are truly relevant to your specific needs and challenges. Don’t be afraid to engage in plenty of deep, technical conversations with the engineers and material specialists you encounter. These experts often hold the keys to understanding how new technologies can be practically applied to your unique situations.

However, it’s equally important to consider your options carefully and critically before making any significant decisions. The additive manufacturing space is experiencing explosive growth, and as a result, there are a lot of vendors crowding this space, many offering what appear on the surface to be very similar solutions. This can indeed make it a minefield for buyers. It’s easy to get caught up in the hype or be swayed by superficial features. My strongest recommendation is to look beyond just the hardware. You absolutely do not want to be sold simply “a grey box” – a standalone machine – and then be left to figure out, often through trial and error, what to do with it and how to integrate it effectively into your operations. That approach can lead to frustration, wasted resources, and unmet expectations.

Instead, focus on identifying vendors who are as deeply focused as you are on the end-use application and the final product that you want to make, or indeed, make better and faster. If the vendor demonstrates a profound understanding of your industry, your specific part requirements, and your business goals, and offers a comprehensive ecosystem that includes not just the printer, but also optimized materials, intelligent software, and dedicated application support, then you are most likely on the right track. A true partner in additive manufacturing will help you navigate the complexities, optimize your designs, and ensure that your investment yields tangible, transformative results for your business. Seek out solutions that promise an integrated workflow and a clear path to production success, not just a piece of equipment.

Don’t forget to claim your free EXPO pass (usually $125) with the code “3DNATIVES” HERE. Will you be visiting Carbon at RAPID + TCT 2025 at booth #2848? Let us know in a comment below or on our LinkedIn, Facebook, and Twitter pages! Don’t forget to sign up for our free weekly Newsletter here, the latest 3D printing news straight to your inbox! You can also find all our videos on our YouTube channel.