In 2021, additive manufacturing continued its steady ascent as a transformative fabrication method, with notable developments spanning industrial-scale systems, novel materials, and inventive applications from independent makers. The breadth of progress underscored both the maturing of professional-grade platforms and the ingenuity of small-scale experimentation.
Argentinian manufacturer Trideo introduced a large-format printer, the Big T, distinguished by its one-square-meter build area and mobility via integrated wheels. This scale enables production of sizable components without segmenting them into smaller parts, a capability of interest for aerospace tooling and automotive prototyping. Stratasys demonstrated the capabilities of its J8 PolyJet systems, producing intricate, multi-material prints with striking realism. The company’s VeroUltra material replicated textures such as wood grain, glass transparency, and even the nuanced visual effects of LED displays. One example—a printed bottle complete with label—was fabricated in a single operation, illustrating the potential for reducing assembly steps.
Desktop Metal advanced binder jetting technology, a process deploying inkjet heads to deposit binding agents onto powder beds. This approach can achieve throughput roughly 100 times faster than laser powder bed fusion, offering significant productivity gains for high-volume manufacturing. Its subsidiary Forust applied binder jetting to create wood-like parts from sawdust, achieving convincing aesthetic fidelity in photographic evaluations.
For cost-conscious users, Mosaic Manufacturing’s Palette 3 Pro expanded the color capabilities of single-nozzle FDM printers by splicing up to eight filaments. Researchers at the University of Southern California engineered a mechanical bed system for FDM printers that eliminated the need for support structures, potentially reducing material waste and post-processing time.
Biomimetic insights also shaped advances. Purdue University researchers, studying lobsters and crustaceans, identified that spiral-layer deposition enhances structural resilience by arresting crack propagation. Similarly, RMIT University in Australia found that varying deposition patterns in 3D-printed concrete improved load-bearing performance. At Spain’s Polytechnic University of Valencia, recycled plastic was used to fabricate an alternative to reinforced concrete beams, pointing toward sustainable construction materials.
In Switzerland, ETH Zürich collaborated with Zaha Hadid Architects to print concrete at specific angles, enabling a bridge design that reduced material usage while unlocking new architectural forms. Commercial adoption moved forward as Habitat for Humanity began constructing its first 3D-printed houses, and Icon offered 3D-printed homes for sale in Austin, Texas.
On the maker side, practical modifications and inventive designs proliferated. Stefan from CNC Kitchen demonstrated a method to reduce printer noise for under two dollars. A viral fractal vise design inspired product designer Christopher Borge to adapt it for 3D printing. MakerPaul created a resettable hourglass-style timer, while engineer Akaki Kuumeri integrated 3D-printed flexures into an Xbox controller for enhanced ergonomics. Industrial design student Charlie Ransford developed a functional 3D-printed turntable.
Novelty also found its place. Oodesign marketed a rubber-band-powered insect cage, and mechanical engineer Yuto Kuroki modified a printer to assemble sandwiches, underscoring the versatility of motion control systems in unconventional contexts. TreeHugger Systems designed low-cost printed tools to improve camping experiences, exemplifying how accessible fabrication can support niche product development.
For those seeking cultural enrichment alongside technical exploration, the Scan the World Open Source Museum released over 17,000 digital scans of notable artworks for free download and printing. This resource merges digital preservation with tangible reproduction, offering engineers and designers an expansive library of forms to study, replicate, or adapt.