RAPID + TCT 2022: Unveiling the Future of Additive Manufacturing and 3D Printing Innovation

The North American additive manufacturing landscape is constantly evolving, driven by relentless innovation and increasing demand for advanced production solutions. At the forefront of this evolution stands RAPID + TCT, the continent’s most significant event dedicated to 3D printing and additive manufacturing technologies. This year marked a momentous occasion as the event celebrated its 30th anniversary, taking place from May 17th to 19th in Detroit, Michigan. Organized through a collaborative effort between SME and Rapid, two stalwarts in the 3D technology event industry, RAPID + TCT 2022 promised to be a pivotal gathering. The industry buzzed with anticipation, especially in light of the Biden Administration’s strategic initiatives to bolster additive manufacturing adoption across the USA, signaling a new era of growth and investment. As a leading voice in the 3D printing community, 3Dnatives was on the ground, committed to bringing you the most comprehensive coverage and insights from this landmark event. Before delving into the detailed happenings, we’ve prepared an exclusive preview, highlighting the groundbreaking developments and exciting showcases from some of the biggest names in the 3D printing sector. Get ready to discover what truly captivated attendees and shaped discussions at RAPID + TCT 2022.

AON3D Revolutionizes High-Performance Material Printing with Duplication Mode

In a significant leap forward for the FFF (Fused Filament Fabrication) 3D printer market, AON3D made a headline-grabbing announcement at RAPID + TCT 2022: the unveiling of its “High Temperature Duplication Mode.” This innovation addresses a critical and growing need within the additive manufacturing industry: the rapid, scalable production of high-performance parts with minimal post-processing requirements. As 3D printing continues its widespread adoption across an ever-expanding array of industrial sectors, users are increasingly seeking solutions that combine speed, efficiency, and the ability to work with advanced engineering-grade materials. AON3D’s new firmware update for its AON M2+ High-Temperature 3D Printer is designed to meet this demand head-on. The Duplication Mode allows the printer to operate two print heads simultaneously, effectively doubling throughput when producing identical parts. This capability is particularly impactful for high-performance, often difficult-to-print materials, which typically require precise temperature control and robust extrusion systems. This breakthrough promises to significantly reduce manufacturing times and costs for complex industrial applications. Beyond this groundbreaking feature, AON3D’s booth also served as a showcase for an impressive suite of new high-performance materials. These included Zymergen Z2 Polyamide, known for its excellent mechanical properties and chemical resistance; VICTREX AM™ 200 LMPAEK™ (low-melt polyaryletherketone), a high-temperature thermoplastic offering superior strength-to-weight ratios and chemical inertness; and Braskem FL900PP-CF, a carbon-reinforced polypropylene that delivers enhanced stiffness and dimensional stability. These material introductions, combined with the Duplication Mode, underscore AON3D’s commitment to pushing the boundaries of what is possible with FFF technology in industrial settings.

Desktop Metal Showcases Expansive Portfolio and 300+ Production Parts

The past few years have been nothing short of transformative for Desktop Metal, a company that has strategically transitioned from a promising startup to a formidable leader in the additive manufacturing market. This rapid ascent has been significantly fueled by a series of high-profile acquisitions, particularly throughout 2021, which have broadened its technological footprint and market reach. At RAPID + TCT 2022, Desktop Metal proudly presented, for the very first time, applications spanning its vastly expanded Team DM portfolio. This comprehensive showcase highlighted the company’s unparalleled versatility across an impressive range of materials and technologies, including metal, polymer, elastomer, ceramic, composite, and even innovative upcycled wood 3D printing solutions. Attendees had the unique opportunity to witness an astonishing display of over 300 3D-printed production parts, demonstrating the tangible impact and industrial readiness of Desktop Metal’s diverse additive manufacturing platforms. Each part exemplified the potential for additive manufacturing to create complex geometries, reduce waste, and accelerate product development cycles across various industries. Among the many platforms on display, significant attention was drawn to the new ExOne S-Max® Flex robotic sand printer, a testament to Desktop Metal’s commitment to advancing solutions for traditional manufacturing sectors like foundries. This robotic system promises enhanced automation and flexibility in sand casting applications, further bridging the gap between digital design and large-scale physical production. The applications for these showcased parts were remarkably vast, offering compelling examples from critical sectors such as automotive, aerospace, energy, medical, and consumer goods industries. This broad spectrum of solutions solidified Desktop Metal’s position as an end-to-end provider for industrial additive manufacturing, capable of addressing complex production challenges across the global economy.

Dyndrite Poised for Major Partnership Announcements and Software Evolution

While specific details remained under wraps prior to the event, anticipation was high around Dyndrite, the visionary developer behind the groundbreaking Dyndrite Accelerated Computation Engine. The company was expected to make a series of significant announcements at RAPID + TCT 2022, hinting at pivotal advancements and strategic collaborations within the additive manufacturing software ecosystem. Dyndrite’s engine is renowned for its ability to dramatically accelerate computation for complex additive manufacturing workflows, from design optimization to machine path generation, enabling unprecedented levels of part complexity and production efficiency. For those eager to delve deeper into these developments, Dyndrite hosted a dedicated press conference on the first day of the event, Tuesday, May 17th, at 10:15 AM EST, directly at their booth. This session was a must-attend for industry professionals and media looking for firsthand insights into the future of AM software. A key highlight was the expectation of new partnership announcements involving industry players such as Azul3D, Impossible Objects, and Meteor Inkjet. These collaborations are poised to significantly expand the reach and capabilities of Dyndrite’s technology, integrating its powerful computational engine with advanced printing systems and materials science expertise. Partnering with companies like Azul3D, which specializes in high-speed, high-performance polymer printing, and Impossible Objects, known for its composite-based additive manufacturing (CBAM) technology, signifies a move towards enabling more complex and demanding applications. The collaboration with Meteor Inkjet, a leader in industrial inkjet printhead driving electronics and software, further underscores Dyndrite’s commitment to optimizing data processing and control for high-resolution, high-throughput AM systems. These strategic alliances are crucial for accelerating the industrialization of additive manufacturing, providing users with more integrated, efficient, and robust solutions across various AM processes.

Essentium Introduces New Materials and IDEX Printer to Advance Industrial AM

Continuing the prevailing trend of industrialization at RAPID + TCT 2022, Essentium, a prominent provider of cutting-edge industrial additive manufacturing solutions, unveiled a host of innovations designed to help companies significantly advance and expand their AM investments and operational capabilities. Essentium’s focus remains on delivering production-scale solutions that push the boundaries of performance and efficiency. A central highlight for interested attendees was the opportunity to experience the Essentium High Speed Extrusion (HSE™) 280i HT 3D Printer. This machine stands out as what the company proudly claims to be the “first true independent dual extrusion system.” This independent dual extrusion (IDEX) technology allows for significant advantages, including the ability to print two different materials simultaneously, print two identical parts in parallel (duplication mode), or even print mirror-image parts, drastically enhancing throughput and versatility. Such a system is critical for industrial users who need to maximize machine utilization and minimize production bottlenecks. Beyond hardware, Essentium also showcased an extensive range of high-temperature materials, developed specifically for production-scale 3D printed parts. These materials are engineered to withstand extreme conditions, offering superior mechanical strength, thermal stability, and chemical resistance, making them ideal for demanding aerospace, automotive, and industrial applications. This impressive materials portfolio was presented in collaboration with Lehvoss, a renowned chemical and mineral specialist. The partnership with Lehvoss underscores Essentium’s commitment to delivering a complete ecosystem of validated hardware and materials, ensuring optimal performance and reliability for critical industrial components. By focusing on both advanced hardware and specialized materials, Essentium is empowering manufacturers to leverage additive manufacturing for truly demanding, end-use production applications, driving greater efficiency and innovation across various industries.

Inkbit Highlights Vision-Controlled Jetting for Production-Scale AM

Inkbit, an innovative additive manufacturing company based in Medford, Massachusetts, has rapidly distinguished itself in the industry, largely thanks to its revolutionary Additive Manufacturing System with Inkbit Vista. This system is celebrated as the first-of-its-kind closed-loop feedback 3D printing ecosystem, offering unparalleled precision and reliability in production. While Inkbit’s AM solutions were only officially launched last year, this MIT spin-off has already made significant waves, securing a prestigious contract with the US Air Force shortly after the successful release of its Vista system. This early adoption by a demanding organization like the Air Force speaks volumes about the robustness and capability of Inkbit’s technology. At RAPID + TCT 2022, attendees had the exclusive opportunity to witness Inkbit’s cutting-edge technology in action. The company’s booth was a hub of activity, showcasing its impressive range of high-performance thermoset plastics. These materials are crucial for applications requiring superior mechanical properties, chemical resistance, and thermal stability, often exceeding the capabilities of traditional thermoplastics. Experts were on hand to provide detailed explanations of how Vision-Controlled Jetting (VCJ) technology can unlock true production-scale additive manufacturing. VCJ integrates computer vision and machine learning to continuously monitor and correct the printing process in real-time, ensuring extreme accuracy and consistency, which are vital for industrial applications. This innovative approach minimizes defects, optimizes material usage, and enables the production of highly complex parts with confidence. Furthermore, Inkbit hosted a compelling Tech Hub Session titled “Using Vision-Controlled Jetting for Next-Generation Industrial Automation Equipment” on Tuesday, May 17th, at 10:30 am. This session provided deeper insights into how VCJ is transforming manufacturing processes, enabling the creation of advanced components for the next generation of industrial automation. It emphasized the power of combining advanced hardware with intelligent software to achieve unprecedented levels of precision and reliability in additive manufacturing.

Materialise Unveils CO-AM Software for Advanced Serial AM Production

Just prior to RAPID + TCT 2022, Materialise, a globally recognized leader in 3D printing software and solutions, made a significant announcement with the introduction of its innovative CO-AM software platform. This new offering is strategically designed to propel the additive manufacturing industry forward, specifically targeting the advancement of serial AM production. CO-AM is positioned as a comprehensive, cloud-based software suite that provides manufacturers with unparalleled access to a full spectrum of tools. These tools are meticulously crafted to manage and optimize every single stage of additive manufacturing operations, from initial design and data preparation to production scheduling, quality control, and post-processing. For Materialise, the introduction of CO-AM is not just about new software; it represents a pivotal step in democratizing and industrializing additive manufacturing. The company emphasizes that empowering more users with robust, scalable tools is essential for transitioning AM from prototyping to full-scale production. A cornerstone of the CO-AM platform is its strong emphasis on automation. Materialise highlights the critical importance of automation in developing unique, reliable, and repeatable workflows – a non-negotiable requirement for any manufacturing process aiming for consistency and efficiency at scale. By automating repetitive tasks and streamlining complex processes, CO-AM aims to reduce manual errors, accelerate production cycles, and lower operational costs. Furthermore, the cloud-based nature of CO-AM ensures flexibility and accessibility, allowing teams to collaborate seamlessly regardless of their physical location. This centralized approach fosters better data management, improves decision-making, and enhances overall operational transparency. Attendees at RAPID + TCT 2022 had the opportunity to explore CO-AM in detail at Materialise’s booth, where experts demonstrated how the software integrates various tools and services, creating a cohesive ecosystem for managing the entire AM workflow. This strategic launch firmly positions Materialise at the forefront of the digital transformation of additive manufacturing, enabling businesses to unlock the full potential of 3D printing for serial production.

Senvol Collaborates with Northrop Grumman on Machine Learning for AM at RAPID + TCT 2022

For those keenly interested in the intersection of data science, machine learning, and additive manufacturing, Senvol offered several compelling reasons to visit RAPID + TCT 2022. The company, a leading provider of data and analytics for additive manufacturing, made a significant impact through both presentations and direct engagement at their booth. A highlight of the event was the featured presentation titled “Improved Process Parameter Optimization Using Machine Learning.” This session brought together Senvol President Zach Simkin and representatives from Northrop Grumman, a global aerospace and defense technology company. Together, they briefed attendees on the crucial technical results of a recently completed America Makes program. This program focused intensely on leveraging a machine learning-enabled approach for process parameter development in additive manufacturing. Optimizing process parameters is notoriously complex and time-consuming in AM, often requiring extensive trial and error. The research presented demonstrated how machine learning algorithms can analyze vast datasets to identify optimal parameters more rapidly and efficiently, leading to improved part quality, reduced development cycles, and cost savings. This collaboration between Senvol and Northrop Grumman, under the aegis of America Makes, underscores the industry’s drive towards more intelligent and data-driven manufacturing processes. In addition to this insightful presentation, attendees were encouraged to visit Senvol’s booth to delve deeper into their comprehensive suite of AM data products. This included the renowned Senvol Database, which is the industry’s most comprehensive database of additive manufacturing machines and materials. Other offerings included the Senvol API, enabling seamless integration of AM data into existing systems; Senvol Indexes, providing valuable market insights; Senvol SOP (Standard Operating Procedures), for best practices; Senvol ML, a platform specifically designed for machine learning applications in AM; and Senvol Services, offering custom data solutions and consulting. Collectively, these products and services are designed to empower manufacturers, researchers, and engineers to make more informed decisions, accelerate material and process development, and ultimately scale their additive manufacturing operations effectively. Senvol’s presence at RAPID + TCT 2022 firmly established its role as a critical enabler of data-driven innovation in the AM sector.

SPEE3D Showcases World’s Fastest Metal 3D Printers and First Cold Spray Wheel

SPEE3D, a pioneer in high-speed metal additive manufacturing, drew significant attention at RAPID + TCT 2022 with its patented cold spray metal technology. This innovative process is widely recognized as one of the fastest metal 3D printing technologies available on the market, offering unparalleled speed and efficiency for creating robust metal parts. Its versatility extends across a diverse range of industries, including demanding sectors such as aerospace, automotive, marine, and defense, where the rapid production of functional, high-strength metal components is critical. For those eager to witness the capabilities of the world’s fastest metal 3D printers firsthand, SPEE3D’s booth was an essential stop. The company not only showcased its impressive lineup of machines but also unveiled a groundbreaking achievement: the world’s first cold spray 3D printed wheel for automobiles. This debut highlighted the technology’s potential for producing large, complex metal parts with significant structural integrity and speed, challenging traditional manufacturing methods. The ability to print such a substantial and critical component like a wheel demonstrates the material strength, precision, and geometric freedom achievable with cold spray additive manufacturing. In addition to this major reveal, SPEE3D also conducted live manufacturing demonstrations of copper battery terminals. This showcased the technology’s applicability in emerging markets, particularly for electric vehicles and energy storage, where high electrical conductivity and efficient thermal management are paramount. Copper, a challenging material for many traditional 3D printing processes due to its high thermal conductivity, is effectively handled by SPEE3D’s cold spray method, which avoids melting the material. The cold spray process works by accelerating metal powder particles to supersonic speeds and impacting them onto a substrate, where they bond upon impact without melting. This solid-state process offers several advantages, including the ability to print a wide range of metals, excellent material properties (often superior to those of cast parts), and the elimination of issues like residual stress and distortion commonly associated with melt-based processes. SPEE3D’s demonstrations at RAPID + TCT 2022 underscored its commitment to pushing the boundaries of metal additive manufacturing, providing viable, high-speed solutions for real-world industrial applications.

Stratasys Continues to Innovate and Advance with Key Product Launches and Strategic Mergers

In the weeks leading up to and during RAPID + TCT 2022, Stratasys, a global leader in polymer 3D printing solutions, generated considerable excitement with a series of significant announcements and strategic moves. The company demonstrated its relentless pursuit of innovation across its diverse portfolio, reinforcing its commitment to advancing additive manufacturing capabilities for a broad range of industrial applications. A key highlight was the expansion of its popular F123 series with the addition of two new composite-ready 3D printers. These machines are engineered to handle advanced composite materials, opening up new possibilities for producing high-strength, lightweight parts for demanding industries. Complementing this hardware upgrade, Stratasys also introduced the new FDM® Nylon-CF10 material, a carbon fiber-reinforced nylon filament that delivers exceptional stiffness and strength, ideal for functional prototyping and production tooling. Further solidifying its material leadership, Stratasys significantly expanded its materials ecosystem, unveiling 16 new materials. This extensive addition provides customers with an even wider selection of thermoplastics, elastomers, and specialized resins, catering to diverse application requirements across various sectors. On the software front, the company introduced GrabCAD Print™ for its advanced Origin® One and Origin One Dental 3D printers. This integration streamlines workflows, enhances usability, and optimizes print performance for these highly precise photopolymerization systems. However, arguably the most impactful news that reverberated throughout the entire additive manufacturing industry was the announcement of the merger between its subsidiary MakerBot and Ultimaker. This strategic consolidation brought together two of the leading providers in the desktop FDM (Fused Deposition Modeling) 3D printer market. The merger created a formidable entity poised to drive innovation and expand market reach in the professional and educational desktop 3D printing segments. Industry experts viewed this as a game-changer, indicating a significant consolidation and a renewed focus on delivering more robust, integrated solutions to a broader user base. Attendees at RAPID + TCT 2022 were encouraged to visit Stratasys at their booth to learn more about these exciting developments, interact with experts, and see the latest hardware and material innovations firsthand. It was also notable that Ultimaker was present as an exhibitor, offering another opportunity for attendees to gain insights into the implications and future directions of this landmark merger.

Velo3D Pioneers Aerospace AM with NASA-Developed Copper Alloy

The synergy between additive manufacturing and the aerospace industry is undeniable, presenting boundless opportunities for innovation, and Velo3D, a leading metal AM technology company, perfectly exemplifies this powerful combination. At RAPID + TCT 2022, Velo3D showcased a remarkable advancement that underscores its commitment to enabling the production of mission-critical parts for the most demanding applications. The company recently announced the qualification of the copper-chromium-niobium alloy GRCop-42 for use in its Sapphire family of metal 3D printers. This NASA-developed alloy is a game-changer, specifically conceived to manufacture parts requiring an exceptional combination of high strength and high electrical and thermal conductivity. Such properties are paramount for components like rocket engine combustion chambers, which often incorporate regenerative cooling channels to manage extreme temperatures and pressures during operation. The ability to 3D print GRCop-42 opens new doors for aerospace engineers, allowing them to design and produce complex internal geometries and intricate cooling channels that are impossible with traditional manufacturing methods. Velo3D’s unique “SupportFree” printing capabilities are particularly well-suited for such complex designs, reducing the need for extensive post-processing and enabling greater design freedom. Velo3D’s ambition is to leverage GRCop-42 with its advanced Sapphire machines to produce critical aerospace components that exhibit outstanding oxidation resistance and high-creep strength at temperatures soaring up to 1400°F (760°C). These characteristics are essential for ensuring the reliability and longevity of parts operating in the extreme environments of rocket engines and other high-performance aerospace systems. To illustrate this breakthrough, the first GRCop-42 demo parts manufactured by Velo3D were prominently displayed at their booth throughout the show. These parts served as tangible proof of the alloy’s printability and the superior quality achievable with Velo3D’s technology, offering attendees a glimpse into the future of high-performance additive manufacturing for space exploration and beyond. This development firmly positions Velo3D as a key enabler for the next generation of aerospace innovation.

RAPID + TCT 2022 truly served as a powerful testament to the dynamic and rapidly advancing world of additive manufacturing. From high-performance FFF systems and diverse material portfolios to groundbreaking software solutions and strategic industry collaborations, the event showcased the immense potential of 3D printing to revolutionize production across countless sectors. The innovations presented by companies like AON3D, Desktop Metal, Dyndrite, Essentium, Inkbit, Materialise, Senvol, SPEE3D, Stratasys, and Velo3D underscored a collective drive towards greater speed, efficiency, material versatility, and industrial scalability. These advancements are not just incremental; they represent fundamental shifts in how products are designed, manufactured, and brought to market, promising a future where customized, high-performance parts are produced with unprecedented ease and speed. The event reinforced that additive manufacturing is no longer a niche technology but a mainstream industrial solution poised to reshape global manufacturing paradigms.

For more detailed information about the event, you can always visit the official website HERE. We encourage you to share your thoughts: What aspects of RAPID + TCT 2022 excited you the most? What innovations do you believe will have the greatest impact on the future of 3D printing? Let us know your insights in a comment below or connect with us on our social media channels, including LinkedIn, Facebook, and Twitter. Don’t miss out on the latest updates from the world of additive manufacturing – be sure to sign up for our free weekly Newsletter here, delivering the most pertinent 3D printing news directly to your inbox! Additionally, you can explore all our exclusive videos and in-depth content on our dedicated YouTube channel.