Revolutionary Multi-Material 3D Printing for Electronics
An advancement in additive manufacturing technology that enables the production of fully functional electronic devices from a single machine, combining multiple materials and revolutionizing the prototyping-to-production pipeline.
About
Nectar Labs developed the MAASS (Multi-material Additive Advanced Systems Solutions) 3D printer to transform manufacturing capabilities. This proprietary technology aims to create fully functional electronic devices from a single design using one machine, targeting both mass manufacturing scale and R&D prototyping applications.
Services
Challenge
The project faced complex technical hurdles in developing techniques for 3D printing multiple materials simultaneously - specifically, two or more polymers and metal conductors. Additional challenges included integrating semiconductors and passive components while implementing closed-loop computer vision control systems for quality assurance and improved throughput.
Our Solution
Nectar Labs developed two key prototypes: SHIMMY, a multi-material stereolithographic 3D printer, and FOXTROT, a metal-polymer 3D printer. These systems were designed to address limitations in existing technologies like inkjet multi-material and FDM fabrication, which struggle with metal quality and precision requirements.
The solution overcomes current market limitations, where no companies currently meet the criteria for 3D printing electronic devices at mass manufacturing scale. With a projected market size of $33 billion by 2030 and a 37% compound annual growth rate, MAASS is positioned to capture significant market share.
Key features
Multi-Material Integration
The system uniquely combines polymer and metal printing capabilities, enabling the creation of complex electronic components including interconnects, antennae, and structural electronics. This integration allows for complete design freedom while maintaining high precision and material quality throughout the manufacturing process.
Manufacturing Innovation
Unlike traditional manufacturing methods such as In-Mold Electronics (IME), MAASS offers flexible, cost-effective production without the limitations of nano-inks or single-part design constraints. This makes it ideal for both prototyping and mass production, significantly reducing development time and costs.
Versatile Applications
MAASS enables the production of diverse electronic components, from basic interconnects to complex metamaterials with negative refractive indices. The technology shows particular promise in markets like hearing aids, where 4.73 million units produced annually require customization and could benefit from integrated electronics printing.
Advanced Material Integration
SHIMMY revolutionizes manufacturing by printing both dissolvable and conductive materials. When using dissolvable supports, complex geometries emerge after a simple wash. For conductive materials, SHIMMY enables direct printing of functional electronic elements, from simple traces to complete circuits.
SHIMMY went to market in November 2024, Foxtrot is expected to reach the market late 2025.
Market Impact and Future Applications
The technology is positioned to serve rapidly growing markets in defense, medical, and automotive industries. With over 275,359 patents filed in related fields since 2000, MAASS represents a significant advancement in additive manufacturing capabilities, offering solutions for both prototyping and production-scale manufacturing.
By enabling the production of complex electronic devices like microbatteries, metamaterials, and structural electronics, MAASS is set to revolutionize how electronic devices are manufactured. This technology makes it possible for startups and established manufacturers alike to produce innovative electronic products with unprecedented design freedom and efficiency.
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