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3 Groundbreaking Ways AI Is Reinventing 3D Printing

Artificial intelligence (AI) has reshaped numerous industrial processes, and many people are exploring the potential of AI 3D printing. Several have already discovered how 3D printing can help them get jobs done faster, less expensively and with better accuracy. How could AI further accelerate this progress?

1. Improving Design Decisions

Some people are getting impressive results using AI during the design phase for their AI creations. This does not necessarily mean users can create fully functional, 3D-printed products without experience. However, it could substantially reduce the time they usually spend designing items before printing them.

One startup called Luma has released a generative AI tool that can create low-resolution 3D image models from text prompts in seconds. People can also opt for high-resolution options, although that takes longer. They took at least 15 minutes to create, in some users’ experiences.

In another case, a company specializing in AI 3D printing for metals and polymers released a commercial printer integration that aims to reduce waste associated with creating advanced parts, such as those used in the aerospace industry. The solution relies on physics-informed AI technology to analyze the components in uploaded print files. The program then automatically corrects thermo-mechanical problems by analyzing process parameters and the scan strategy.

This AI 3D printing approach allows people to proceed without making various physical iterations to test designs or using expensive element simulation tools. One California-based provider of rocket-launch equipment used the design product to overcome an overheating issue that repeatedly caused 3D printing failures. The AI functionality enabled the digital iteration necessary to tackle this obstacle. It also allowed the customer to pursue a design with 80% fewer support structures, making the overall cost per part 30% lower.

There’s also the case of a 3D printing company working to create Portugal’s first house with this method. The company behind the project used AI to design the inside and outside of the residence. Representatives expect 3D printing to make more than 484 square feet of walls in 20 hours.

2. Disrupting Automotive Creations

Some automotive companies have begun addressing shortages and maintaining lean supply chains with on-site 3D printers. Such a strategy also supports innovation, which is particularly important with more automakers prioritizing sustainability.

A father and son team worked with AI 3D printing possibilities when designing a futuristic car they call Czinger 21C. It’s the flagship offering of their Czinger Vehicles business. Described as  “the world’s first human/AI-designed and 3D-printed hypercar,” this vehicle goes from 0 to 60 mph in 1.88 seconds. It also reaches speeds of up to 253 mph, making professional racecar drivers the target audience.

However, the father and son intend to make this a street-legal car, anticipating it will be the fastest of its kind. The pair used a proprietary AI solution called the Divergent Adaptive Production System that works as a hardware-software product when making this vehicle. That platform relies on AI to computationally design even complex structures. It then uses 3D printing to create and assemble the parts, optimizing each component to make it as strong and lightweight as possible. This method reduces structural mass by 20%-40%.

The production method also adapts, making it as suitable for cars as substantially different products, such as drones. Moreover, the platform makes each component from recycled metal, which can be used for other products at the end of an item’s useful life.

3. Delivering Personalized Products

The affordability and vast number of accessible resources covering 3D printing make it open to everyone, from hobbyists to professionals. It also helps that companies use 3D printers to bring more products to the masses. People’s curiosity could result in them wanting to know more about the technology behind the merchandise.

AI 3D printing techniques are ideal for tailor-made consumer products. One company combined the two technologies to create personalized skin care supplements. The process starts when people scan their faces with an artificial intelligence app that captures more than 100,000 skin pixels and more than 20,000 attributes of the face and skin. Next, artificial intelligence analyzes details such as blemishes and wrinkles, applying a relevant score based on the results.

Finally, customers take a short lifestyle quiz and receive a gummy recommendation based on all the associated data. The AI-printed consumable will include seven nutrients to improve the person’s skin. Representatives said the company uses that option over traditional manufacturing methods because of the need for small and highly customized production runs.

This business model makes sense because most people understandably don’t want to spend money on something without having a strong confidence it will work well for them. Since AI enables so much personalization, consumers can feel better that it’s tailored for them and is more likely to produce results.

Adding Custom Design Elements to Existing Models

Although user-generated 3D models are widely available, most are difficult to customize, especially if users don’t have or are unfamiliar with computer-aided design software. However, researchers built a generative AI-powered tool that helps people add the desired customization by using natural language prompts. That makes it easier to experiment with using a 3D printer, even without prior experience with customization.

The tool automatically separates the model into aesthetic and functional elements, making the design phase faster. This approach also increases the chances of the user’s modified product working as they expect after printing.

The researchers also believe people could use their tool to streamline the creation of customized medical devices. Specificity to each patient tends to raise user-friendliness, comfort and other desirable aspects. Plus, clinicians may not have the expertise to use other customization tools. The fact someone can use this one by typing phrases to describe what they want significantly elevates its appeal.

AI 3D Printing Projects Are Gaining Momentum

These fascinating examples show that artificial intelligence and 3D printing can be a worthwhile combination that helps people create necessary products faster and more competently. However, using these two technologies together will likely work best when people have clear ideas of what they want to achieve before starting.

Emily Newton is the Editor-in-Chief of Revolutionized Magazine. She has over six years experience writing articles for the tech and industrial sectors. Subscribe to the Revolutionized newsletter for more content from Emily at