Microbially induced calcium carbonate precipitation (MICP) offers a low-energy, carbon-efficient alternative to traditional mineral material production, yet its integration into digital fabrication for architectural applications remains limited. This research presents a design-to-biofabrication workflow that combines computational geometry, robotic extrusion-based 3D printing and MICP. The study introduces a methodology that uses porosity, surface-area-to-volume (SA/V) ratio, interlayer connectivity and overhang capacity as coupled design parameters that balance biocementation requirements and fabrication constraints. Through iterative testing of triply periodic minimal surfaces (TPMSs) geometries, an “Optimized Unit” was developed and refined to improve printability and biomineralization efficiency. The workflow is validated through a 1 m2 architectural partition wall demonstrator that illustrates the potential for modular biomineralized architectural components. The results show that calibrated geometric control enables stable extrusion while enhancing mineral distribution, demonstrating a pathway towards architecturally scaled bio-fabricated mineral components.

Residual stress is inherent in Additive Manufacturing process due to the heat cycling of the material being deposited on the build plate. The manufacturing toolpath can have a considerable effect on the development of residual stress distribution within a component. This paper examines the impact of the shell feature to generate some design heuristics on whether to include it when residual stress is of concern. The stress feature did increase the residual stressed observed during printing but was mitigated by the cooling regime after the process was complete.

Additive manufacturing (AM) eases conventional manufacturing (CM) constraints allowing new design freedom. Yet designers still rely on experience and face AM high energy demand and variable waste benefits. This paper introduces an ecodesign approach to AM workflow through a tool comparing AM and CM via lifecycle metrics. The tool anticipates design and sustainability challenges providing environmental insights already at initial stages. This is highlighted with two use scenario: a new design and a redesign task. Future work involves tool development and validation with industrial case studies.

This design-led study explores how circular economy principles can be embedded in research prototyping while comparing environmental sensing methods. A reusable outdoor prototype, deployed in three contexts, combined embedded sensors and API data. Using proxy indicators (energy, material mass, emissions) and end-of-life planning, API sensing indicated a far lower impact, while embedded sensing offered hyper-local data. All prototype components were either reused or repurposed, demonstrating circular prototyping in practice, with findings intended as design-informing rather than definitive.

We present a thermal process-monitoring system for MEX tracking layer temperature as a proxy for interlayer adhesion. Python-based hottest-point tracking by infrared thermography is implemented on a chamber-heated desktop printer to track nozzle movements and measure the temperature field millimeters ahead of deposition logging the results on a CSV file. We quantify accuracy versus camera distance (Δd=73mm) and probe radius (R2-R5). Where R3-R4 provided just a ΔRMSE of 1.52°C suggesting R3 as the optimal distance. The results can inform mechanical properties in load-bearing AM applications.

E-scooters have cemented their position as a convenient transport solution in urban areas, with hundreds of millions of e-scooter trips completed globally each year. This study investigates and presents useful tyre performance data for 12 e-scooter tyres, including three novel 3D printed tyres made from 90A TPU. The results highlight the potential of 3D printed tyres to provide comparable performance to existing e-scooter tyres. The information presented in this study is useful to better understand the energy losses associated with these devices.

Fused Layer Modeling (FLM) is one of the most popular additive manufacturing techniques. Its application is often limited caused by the procedurally anisotropy. This work addresses FLM’s weakness by examining a new path planning concept that replaces printing several adjacent parallel lines, for example in perimeters. The new technique was compared with conventionally manufactured reference samples in tensile tension and three-point-bending tests. The results show an improvement of the tensile strength in build direction of the samples by up to 40% and a reduction of anisotropy by 28%.

This study evaluates the repeatability of print results in FDM through tests made with a generatively designed robotic limb. Five specimen were printed in two build orientations each with the same other process parameters. Deviations were measured via 3D scanning and CMM on both outer surfaces and functional features. Measured deviations exhibit small mean values and a clear orientation-dependent variability. As findings highlight deterministic effects in the propagation of deviations, design guidelines to improve repeatability of 3D prints are formulated as a result.

This study compares solid and shell generatively designed PLA components for material extrusion (MEX) at matched mass targets (100, 150, 200 g). Geometries were generated Generative Design (GD) and manufactured by MEX, then tested in a 30° quasi-static compression rig representing prosthetic heel strike. Solid designs achieved up to 92% higher peak load, but failed abruptly, whereas shells exhibited lower strength but progressive, energy-dissipating failure. Results show that simple shelling of GD outcomes cannot replace iterative GD refinement for weight-critical, load-bearing parts.

Though additive manufacturing (AM) is well on its way to transform architecture, design, and construction, the integration of sustainable biomaterials capable of reducing the sector’s substantial carbon footprint remains limited. While traditional building materials like concrete, metals and plastics have reached industrial maturity in 3D printing, biomaterials largely remain confined to experimental prototyping due to challenges in performance, durability and scalability. This paper explores the potential of multi-material additive manufacturing (MMAM) to address these limitations and facilitate biomaterial fabrication at architectural scales. Building on a review of material developments in extrusion-based 3D printing, the study proposes and experimentally evaluates novel multi-material strategies that combine slow-curing, paste-based biomaterials with rapidly solidifying thermoplastic biocomposites. Two key approaches are introduced: the “interwoven” strategy layers different materials alternately as internal reinforcement, while the “intertwined” method juxtaposes distinct materials to provide external support. Through small-scale test cylinders and large-scale, application-oriented prototypes, produced with synchronized robotic extrusion systems, the research demonstrates significant improvements in print stability and achievable print height for biomaterial 3D printing. While challenges remain concerning inefficient fabrication workflows, material system optimization, and regulatory validation, the findings outline a viable pathway towards scaling biomaterial 3D printing and advancing a more sustainable, material-conscious architectural production.

Additive manufacturing is enabling on-demand fabrication of desirable polymer designs. Due to the technology’s widespread use, there is a need to ensure sustainable design approaches are practiced. Here, thermoplastics for fused deposition modeling is reviewed for life-cycle stages, mechanical properties, and design strategies. Life-cycle stages assessed include formulation, processing, applications, and end-of-life as well as recycling processes. Mechanical properties are considered for recyclable thermoplastics, with fillers to enhance functionality. Finally, design methods are considered to create mechanically efficient designs, such as metamaterials, that reduce material usage and processing time. The review highlights the great potential for creating sustainable designs with additively manufactured polymers, and their mechanical capabilities for broad applications.

Medical phantoms are models used for imaging and therapy, enabling research, quality assurance, and training without human test subjects. Their development relies on selecting tissue-mimicking materials, however the lack of a holistic overview to guide this process poses challenges. This work presents a comprehensive design catalogue for phantom materials, offering a structured overview of materials and their imaging properties for computed tomography (CT), magnetic resonance imaging, and ultrasound, including parameters such as CT numbers, relaxation times, and acoustic properties. It is implemented as a digital tool with filtering options, enhancing usability and decision-making. Despite limitations from incomplete data in the literature, the catalogue establishes a groundwork for a standardized, expandable resource to support future phantom design.

This paper provides a design solution to the existing problem of using eye trackers for large screens. Traditional eye trackers are limited to commercial and smaller-sized screens. However, as larger screens become increasingly popular and essential for various tasks, their impact needs further investigation in user performance and behavioral studies. This work introduces a design approach for adjustable guide rail system to make moving an eye tracker along with the user's head position possible. The testing results showcase robust, accurate and functions under varying real-world conditions, making it ideal for Human-Computer Interaction and User Experience Research. The Guide Rail design employed by this system is easy to manufacture and incorporates 3D printed parts making it easily reproducible and open for customization.

The ability to modify designs, personalize nutrition, and improve food sustainability makes 3D food printing (3DFP) an exciting emerging technology. Food materials’ complex chemistry and mechanics make it difficult to consistently print designs of different shapes. This research uses two methods to assess printed food fidelity: Manual and automated image analysis with custom-developed algorithm. Fidelity based on printed area was measured for three overhang designs (0°, 30°, and 60°) and three food ink mixtures. The manual method provided a baseline for analysis by comparing printed images with CAD images. Both methods showed consistent results with only ±3% differences in analyzing printed design areas. While the computational method offers advantages for efficiency and bias reduction, making it well-suited for fidelity assessment to assess designs.

Biodegradability is often framed as an intrinsic material property. By integrating industrial design and soil science, this research examines how material design can actively support ecological reintegration. Through a case study of Polylactic Acid (PLA)—marketed as sustainable yet resistant to breakdown in everyday soil—we challenge how biodegradability claims misalign with real-world decomposition. To address this, we designed and tested 3D printing filaments, using compost respiration analysis to show that microbial engagement depends on material composition and environmental factors. We then introduce decayability as a novel affordance that supports microbial activity. By extending affordance theory beyond human perception, this study establishes a framework for designing materials that mediate interactions between human fabrication needs and nonhuman decomposition processes.

3D food printing is transforming the food industry by enabling the production of customized, on-demand foods with intricate designs. However, achieving high shape fidelity remains a challenge for optimized food ink formulations. This study investigates 3D-printed foods with overhang designs using extrusion-based 3D printing. Mashed potato and pea protein were selected as base ingredients with varied water content to assess their differences in moisture content (70–87%), pH (5.66–7.06), firmness (0.52–8.12 N), and adhesiveness (0.29–2.73 N·s). Shape fidelity was evaluated by printing geometries with overhang angles of 0° and 60°. Results showed the best printability at a 1:4 ratio (81% moisture) for mashed potato and 1:3.5 ratio (78% moisture) for pea protein. These insights provide guidelines for engineering high-fidelity food inks, that advances additive manufacturing in food design.

This paper presents four new monolithic continuum robot designs that can be 3D printed in a single piece and with TPU or similar elastic filaments for either educational or experimental applications. Similar tendon-driven continuum robots are usually made of a flexible backbone (often in NiTi alloys) and rigid vertebrae, with tens of components in a robot segment resulting in time-consuming manual assembly and high costs. Conversely, the proposed designs achieve equivalent functionality while avoiding the manufacturing challenges. Additionally, by removing the need for coupled features for assembly and 3D-printing backbones and vertebrae as a single part, new geometries are possible and can be explored to tailor robot performance to specific requirements. To validate the proposed design, four sample prototypes have been manufactured and experimentally tested. The obtained results, when compared to the piecewise constant curvature model, demonstrate a 3.06% tip positioning error and limited reduction of the workspace area of 23.07%, which compares favorably to similar but more expensive and complex tendon-driven robots.

This is a case of a 6-week-old male with D-TGA and multiple large ventricular septal defects who presented with oxygen desaturations into the 60s. He had initially undergone palliative pulmonary artery banding at a different institution, for concern that patch closure of his large ventricular septal defect would compromise ventricular function. We decided to undergo 3D printing and 4D modelling of his heart to delineate his ventricular septal defect anatomy in preparation for their closure and arterial switch operation. A 4D CTA showed a large perimembranous outlet ventricular septal defect and a very large “swiss cheese” muscular defect. We then segmented the heart and produced 3D models of the diastolic and systolic phases and printed 1- and 1.5x-sized 3D heart models. The 3D and 4D models were used to evaluate all ventricular septal defects from both sides of the ventricular septum to plan their closure. The systolic phase of the CTA demonstrated near obliteration of the apical muscular ventricular septal defects. The patient underwent complete surgical repair at 4 months. The posterior septal, apical, and large anterior muscular ventricular septal defects were closed by bovine pericardium. However, the large perimembranous and inlet ventricular septal defects were closed with a single patch, sparing the intervening muscle band that was thought to contain the conduction system. From the models, the most distal apical ventricular septal defects were shown to close with ventricular contraction during systole. Therefore, apical exclusion of the RV was not required. Thus, this additional information enabled an optimal surgical approach to efficiently close ventricular septal defects in need of closure without futile attempts at closing remote ventricular septal defects.

3D printed orthomode transducer (OMT) integrated with a 3D printed lens antenna is presented in this work. The OMT integrated with the lens antenna covers the range of 54–80 GHz, the radiator can handle a fractional bandwidth of 38%. Fused filament fabrication printing process is used for the domed elliptical profile lens antenna and polyjet printing process is used for fabrication of the OMT. The simulated radiation efficiency of the antenna remains above 90% for the entire bandwidth and the structure shows a gain of above 16 dBi.

BioForms integrates sacrificial formworks, agent-based computational algorithms and biological growth in the generation of biodegradable internal wall panel systems. These wall panel systems are intended to minimize material waste, utilize local botany and generate a symbiosis between the artificially made and the naturally grown. This is achieved by utilizing local waste as a structural compressive core, mycelium as the binder, and recycled pellets as the architectural skin. Leveraging mycelium’s structural, acoustic and thermal properties, this exploration delves into unique methods of incorporating fungi and waste into architectural construction. The motivations for this research stem from the need to address the building industry’s contribution to climate change, by considering the lifecycle of our materials. BioForms aims to retrofit existing buildings by replacing foam insulation and MDF (medium-density fiberboard) wall panels with biodegradable and recyclable 3D-printed skins embedded with a mycelium core. Analysing mycelium’s reaction to BioForms I, the second iteration, BioForms II, evolves in design complexity and materiality. BioForms II explored robotically fabricated wood-based polylactic acid plastic (PLA) composite materials. Within the second iteration of this research stream, mycelia was both embedded within the compressed fabricated skins and on the external surface. Whilst BioForms explored the generation of biodegradable wall panel systems, the broader aims of this research is aimed at infiltrating biological matter into human-occupied spaces, completely omitting the use of synthetic building materials within the construction industry and advancing the architects relationship to nature in the generation of form.