Scientists at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) have developed a powerful new 3D-printing system that could transform how large and complex parts are manufactured.
The new approach combines several smaller 3D-printing extruders into one coordinated, high-output flow, allowing printers to work faster, more precisely, and with multiple materials at the same time.
Traditionally, large-scale 3D printing relies on big, heavy extruders that push out large amounts of molten material.
While fast, these systems come with serious drawbacks. Their weight requires stronger and more expensive robotic arms, and when printing smaller or detailed parts, the material flow can become uneven.
This often forces printers to slow down to avoid overheating, warping, or failed prints—especially when making parts that change thickness or shape.
ORNL’s new system takes a different approach. Instead of relying on one massive extruder, it uses several smaller ones working together through specially designed nozzles.
These smaller extruders are lighter, easier to control, and can be turned on or off as needed.
When combined, they can match or even exceed the output of traditional large extruders—without sacrificing accuracy.
One of the most exciting features of this system is its ability to print more than one material at the same time, within a single printed line, known as a bead. Normally, switching materials requires stopping the print and changing equipment.
ORNL’s design makes it possible to print different materials together continuously, opening the door to parts that blend strength, flexibility, heat resistance, or other properties in a single piece.
“At the same time, we’re reducing weight, improving precision, and enabling new kinds of multi-material designs,” said ORNL researcher Halil Tekinalp, who led the project.
He added that the technology could help strengthen U.S. manufacturing and make advanced production tools more accessible.
This flexibility makes the system useful across many industries. In aerospace, it could be used to create lightweight panels that absorb impact or reduce radar signals.
In energy applications, it could help produce flame-resistant housings, battery supports, or modular structures needed for modern power systems. Defense and construction teams could use it to print strong, lightweight shelters, bridge components, or protective panels. Even everyday products like car bumpers or boat hulls could benefit from this technology.
At the heart of the innovation are new, patent-pending nozzles made from aluminum bronze, a material chosen for its strength and ability to handle heat. Inside these nozzles, molten materials from multiple extruders are carefully merged. A Y-shaped internal design improves material flow and reduces tiny air gaps, which can weaken printed parts.
The team also developed a special nozzle that creates “core-and-sheath” beads, where one material forms the outer shell and another forms the core. This structure improves bonding between layers and helps prevent delamination, a common problem in 3D-printed polymers where layers separate under stress.
“This technology lets us combine materials precisely while keeping them separate and pure,” said project co-lead Vipin Kumar. With this new system, manufacturers could design smarter, stronger, and more creative products—printed faster and more reliably than ever before.
Source: Oak Ridge National Laboratory.
