ORNL Multiplexed Extrusion System Could Triple Large-Format 3D Printing Speeds

Researchers at Oak Ridge National Laboratory (ORNL) have developed a multiplexing extrusion system that could significantly accelerate large-format 3D printing while maintaining precision and enabling multi-material capabilities.

How It Works

The system uses a Y-shaped nozzle design that combines multiple smaller extruders into a single high-output stream. According to project lead Halil Tekinalp, this approach enables smaller extruders to achieve the output of larger systems without the additional weight burden.

By enabling smaller extruders to achieve the output of larger systems without the additional weight burden — while also enabling previously unattainable multi-material extrusion within a single strand — this system has the potential to redefine extrusion-based additive manufacturing, said Tekinalp.

Multi-Material Capabilities

Beyond speed improvements, the system introduces what ORNL calls core-and-sheath beads — where one material encases another within a single extrusion line. This opens new possibilities for combining materials with different mechanical or functional properties.

The innovation also addresses delamination issues in polymer additive manufacturing. This innovation opens up new manufacturing horizons, making it possible to achieve complex, efficient and creative designs with dynamic material switching, all while preventing cross contamination, said researcher Vipin Kumar.

DOE Funding

The project was funded by the DOE's Office of Critical Minerals and Energy Innovation, through the Advanced Materials and Manufacturing Technologies Office (AMMTO). Research was conducted at ORNL's Manufacturing Demonstration Facility, a nationwide consortium focused on innovating U.S. manufacturing.

The technology could have significant implications for aerospace, automotive, and industrial manufacturing sectors that rely on large-format additive manufacturing.