Oak Ridge Lab Unveils New 3D Printing Extrusion System for High-Efficiency Automotive Bumper Production

Researchers at the Department of Energy’s Oak Ridge National Laboratory (ORNL) have recently developed a novel 3D printing extrusion system that integrates multiple small extruders into a single high-output stream through a specialized nozzle, achieving high speed, high precision, and multi-material printing capabilities. Unlike conventional large extruders—which rely on expensive, heavy machinery and often suffer from reduced accuracy and heat buildup at low flow rates—this new system allows flexible addition or removal of extrusion units without compromising print quality. It also enables simultaneous multi-material printing within a single nozzle, eliminating the need for equipment changes. The technology is particularly well-suited for efficiently manufacturing complex components such as automotive bumpers and holds significant potential for broad application across the automotive and other industries.