Page 9 - Summer 2025

Industry News

3D-printed Electronics accelerate Quantum Improving Metal 3D-printing
Sensor Innovation
Metal additive manufacturing uses a high-powered
In a related article entitled ‘A Quantum Leap laser to selectively fuse fine metallic powder so as to
Forward: How 3D-printed Electronics are build parts layer by layer from a precise 3D model,
accelerating Quantum Sensor Innovation at the creating complex, highly customised components
University of Stuttgart’, Oliver Johnson explains with minimal material waste. It is frequently
in Med-Tech Insights, June 24th., how the BMBF hindered, however, by the hitherto high cost of
FOCUS ON ADDITIVE Cluster4Future QSens initiative is pioneering having to determine optimal process parameters
transformation in the field of quantum sensor
by trial and error.
technology, bridging the gap between academic
MANUFACTURING research and industrial applications. Now, researchers at the University of Toronto have
developed a new framework known as the Accurate
The author states: Inverse Process Optimisation Framework in Laser Directed
Energy Deposition (AIDED) that quickly identifies the
“QSens “Quantum Sensors of the Future” - a
optimal process parameters for the application required.
consortium comprising fifteen industrial partners,
the Universities of Stuttgart, Ulm and Tuebingen, the A closed-loop system uses a generic algorithm that
Charite in Berlin, and three research institutions - has mimics natural selection to determine optimal solutions.
set itself the task to pioneer the advancement of This first suggests combinations of process parameters
quantum research at an unprecedented pace. With and then applies machine learning to evaluate printing
Reshaping Product Development with Additive “Together with the University of Stuttgart and the the ambitious mission to bring quantum sensors to quality. The algorithm then verifies these predictions
Manufactured Electronics BMBF Cluster4Future QSens, we are leveraging our the market over the next five to nine years, the group iteratively until the best parameters are found.
multi-layer, multi-material DragonFly IV 3D-printer sought a solution that would address key challenges
This article, by Nir Sade, General Manager of and allow for the scalable integration of electronics, Numerous experiments were conducted to collect
to accelerate advancements in quantum devices.
Nano Dimension, in the May 2025 issue of Design photonics and quantum sensor technology, while vast data set with the aim of developing an enhanced
Solutions (p.26-27) explores how additive To instil trust in the AME offering, we are working reducing the time and cost investment that typically autonomous, or ‘self-driving’ additive manufacturing
manufactured electronics is rapidly emerging with IPC, the global organisation for electronics restricts accessibility”. system.
as a transformative alternative to traditional manufacturing, to develop IPC Standard 2851 - The solution that was adopted was AME with DragonFly First Author of the study Xiao Shang, states:
prototyping and production techniques. a dedicated standard for the qualification and IV, which the University of Stuttgart integrated into
production of 3D-printed electronics. “We have demonstrated that our framework
Additive manufactured electronics are noted its research workflow and manufacturing platform can identify optimal process parameters from
particularly for revolutionising R and D in the We are expecting there to be breakthrough Quantum4SME. customisable objectives in as little as one hour,
electronics industry by providing greater freedom of developments in the way AME is used soon, This combined additive manufacturing with the ability to and accurately predicts geometries from process
design through geometry, allowing for the creation of as customers we’re working with have already print both conductive and non-conductive materials in parameters. It is also versatile and can be used with
smarter and smaller products with integrated non- qualified the first applications to be manufactured a single process, provides the ability to create complex various materials”.
planar electronics. Designers can simultaneously using the benefits of AME.” multi-layered electronic circuits and, critically, the
3D-print conductive and dielectric materials so as to heterogeneous integration of quantum devices. This Yu Zou, Professor of Materials and Engineering in the
produce completely new designs, including integrated enables the creation of specialised quantum devices, Faculty of Applied Science and Engineering at the
printed components such as twisted coils, capacitors such as those used to measure brain activity or nerve University of Toronto, adds:
and any angle connections of conductors. These signals in med-tech and those used to evaluate atomic “ By combining cutting-edge additive manufacturing
capabilities simplify assembly and improve signal structure in chemical engineering.
methods with artificial intelligence, we aim to create
integrity. Leveraging AME drastically streamlines the multiple a novel closed-loop controlled self-driving laser
Closely related to this is the ability to rapidly prototype stages of design, prototyping and testing, resulting in system. This system will be capable of sensing
rapid prototyping and immediate testing of new designs,
parts in-house, particularly for complex small devices potential defects in real-time, predicting issues before
reducing the time and cost of developing and refining
such as antennas and sensors. The use of digital they occur and automatically adjusting process
quantum sensors.
inventories for on-demand, on-site creation of parameters to ensure high quality production. It will
electronics spare parts is also possible, a major benefit Now installed in a dedicated research building within be versatile enough to work with different materials
when unexpected disruptions prejudice the supply the Center for Applied Quantum Technology (ZA Quant) and part geometries, making it a game-changer for
chain. at the University of Stuttgart, the DragonFly IV is allowing manufacturing industries”.
experts in quantum physics, photonics and engineering
A further benefit is the ability to rapidly 3D-print cost-
science to collectively leverage its capabilities for applied Reference: ‘AIDED Framework for Metal 3D-printing’, International
effective, multi-layer prototype PCBs, streamlining quantum research: Sheet Metal Review, Vol.25, No.5, June 2025, p.19
product development and shortening lead times,
removing dependence on external vendors and “Within months of installation, the 3D-printer has created
allowing the simultaneous printing of multiple designs. a step-change in the pace of research and opened up
entirely new interest areas in a number of fields”.
Additive manufactured electronics, however, is not
Jasmin Atta of the Institute of Smart Sensors, University of
without its challenges. It is still at a relatively early
Stuttgart, comments:
stage of industry adoption, and there is still a lack of an
established knowledge base for designing 3D-printed “Historically, flexible sensors have been extremely difficult
electronics, which several universities and research to produce. Now, with the help of these 3D-printers, we are
institutes are in the process of addressing along with able to achieve any kind of pattern, any kind of design”.
Nano Dimension:

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