In a groundbreaking development for the future of space exploration and biomedical research, Redwire Corporation, a prominent player in the space industry, has announced that its subsidiary, Redwire Space NV, has secured a 14 million euro contract from the European Space Agency (ESA). This exciting partnership aims to develop the 3D-BioSystem Facility, an advanced 3D bioprinting system that will enhance tissue manufacturing capabilities for long-duration space missions and have significant implications for life on Earth.
A Giant Leap for Bioprinting:
The 3D-BioSystem Facility, designed and developed by Redwire Space NV, will be a cutting-edge modular system that harnesses the power of 3D bioprinting technology. With its ability to sustain a multitude of experiments, this facility represents a significant leap forward in microgravity bioprinting capabilities. The system will consist of a 3D bioprinter, 3D cell culture units, and an incubator, enabling the production of tissue samples directly in space. These samples can then be further processed onboard or returned to Earth for further analysis and application.
Paving the Way for Space Exploration:
One of the primary goals of the 3D-BioSystem Facility is to enable long-duration spaceflight to destinations such as the Moon and Mars. The ability to bioprint cell constructs in microgravity is crucial for sustaining astronauts during these ambitious missions. By leveraging tissue engineering and regenerative medicine, the facility will contribute to the development of vital resources and medical treatments for space travelers. Moreover, the system could potentially revolutionize the way we understand cell-to-cell interactions, advance drug efficacy and toxicity testing through organoid creation, and pave the way for printing vascularized tissue and transplantable organ patches.
International Space Station
Advancing Biomedical Research on Earth:
The impact of the 3D-BioSystem Facility extends far beyond the realm of space exploration. By enhancing our understanding of tissue engineering and bioprinting, the facility holds immense promise for improving healthcare and advancing medical research here on Earth. Through studying cell behavior in three-dimensional environments and investigating the effects of microgravity on tissue growth, scientists can gain crucial insights into complex diseases and develop innovative therapies. The facility’s potential applications range from personalized medicine to drug discovery, creating opportunities to address unmet medical needs and improve patient outcomes.
Boosting European Technological Independence:
The partnership between Redwire Space NV and the European Space Agency is also significant in terms of fostering European technological non-dependence and competitiveness. By developing state-of-the-art space infrastructure and leveraging advanced manufacturing techniques, Europe can secure its place as a leader in space innovation. This not only ensures the continent’s access to space benefits but also contributes to the expansion of the global space economy.
International Space Station
Redwire’s Track Record and On-Orbit Capabilities:
Redwire Corporation has established itself as a frontrunner in microgravity bioprinting, exemplified by its BioFabrication Facility (BFF) currently operating on the International Space Station (ISS). The BFF-Meniscus-2 investigation, a collaboration between Redwire and the Uniformed Services University of the Health Sciences Center for Biotechnology, showcases the potential of space bioprinting to treat meniscal injuries. With the 3D-BioSystem Facility joining the ranks, Redwire’s on-orbit capabilities continue to advance biomedical research, plant biology, and advanced materials manufacturing, fostering scientific discovery and facilitating the development of beneficial products for Earth.
The Redwire subsidiary’s contract with the European Space Agency marks a significant milestone in the field of additive manufacturing and space exploration. The 3D-BioSystem Facility’s development represents a
Additive manufacturing technologies are often described by commercial names such as FDM, SLS, SLA, DMLS, PolyJet or WAAM. These names are useful, but they can mix trademarks, historical terms and process physics. A clearer starting point is the seven process categories used by ISO/ASTM terminology.
Choose an additive manufacturing process by how material is delivered, consolidated and supported—not by the popularity of a machine brand.
ISO/ASTM 52900:2021 remains the current confirmed international vocabulary standard for additive manufacturing. It defines AM as creating physical 3D geometry through successive addition of material and organizes the field into standardized process categories.
The seven standard AM process categories
Process category
How the part is formed
Common feedstock
Typical applications
Vat photopolymerization
Light selectively cures liquid photopolymer in a vat
Photopolymer resin or ceramic-filled slurry
Dental devices, models, patterns and fine polymer parts
Material extrusion
Material is selectively dispensed through a nozzle or orifice
Thermoplastic filament, pellets, paste, concrete or bioink
Prototypes, tooling, large-format parts and construction
Powder bed fusion
Thermal energy selectively fuses regions of a powder bed
Polymer, metal or selected ceramic powder
Functional polymer parts, metal components and implants
Binder jetting
Liquid binder selectively joins particles in a powder bed
Metal, ceramic, sand, gypsum or other particulate material
Sand molds, metal parts, ceramics and visual models
Material jetting
Droplets of build material are selectively deposited
Photopolymer, wax, nanoparticle suspension or functional ink
Detailed models, casting patterns and multi-material parts
Directed energy deposition
Focused energy melts material as it is deposited
Metal powder or wire
Repair, feature addition and large near-net metal parts
Sheet lamination
Sheets are bonded and shaped layer by layer
Paper, polymer, metal foil or composite sheet
Models, embedded structures and selected metal components
1. Vat photopolymerization
Vat photopolymerization uses light to selectively solidify a liquid resin. The category includes several light-delivery and layer-separation approaches:
Laser SLA: a focused laser scans the layer.
DLP: a projector exposes a complete layer or projected region.
MSLA/LCD: an LCD mask shapes light from an underlying source.
Continuous-interface methods: reduce discrete peel interruptions through a controlled inhibition or separation zone.
Strengths: fine detail, smooth surfaces, dental and medical material ecosystems, full-layer exposure on projection systems and broad visual-model capability.
Constraints: uncured-resin handling, washing, drying, post-curing, support marks, long-term polymer aging and indication-specific material validation.
Material extrusion selectively dispenses material through a nozzle. The most familiar route melts thermoplastic filament, but the category is much broader.
Filament extrusion: commonly called FFF; FDM is a Stratasys-associated trademarked term.
Pellet extrusion: uses polymer granules for higher material flow and large-format systems.
Paste extrusion: deposits ceramics, food, energetic materials, silicones or other viscous formulations.
Concrete extrusion: deposits pumpable cementitious material for construction elements.
Extrusion bioprinting: deposits cell-containing or biomaterial formulations for research.
Strengths: accessible equipment, wide material forms, low feedstock cost, large build sizes and straightforward multi-material concepts.
Constraints: bead-scale resolution, anisotropy, voids, interlayer bonding, warpage, support needs and variable surface quality.
3. Powder bed fusion
Powder bed fusion spreads a layer of powder and selectively fuses regions using thermal energy. The unused powder supports surrounding geometry, although metal systems often still need supports for heat transfer, anchoring and distortion control.
Polymer PBF
Selective laser sintering is widely used for nylon and thermoplastic elastomer components. Other commercial platforms use alternative heating or fusing-agent strategies while remaining within powder-bed-based polymer production concepts.
Laser metal PBF
Laser powder bed fusion of metal is also described by commercial or historical names such as SLM and DMLS. The standardized process description is clearer: PBF-LB/M, powder bed fusion using a laser beam for metallic material.
Electron-beam metal PBF
PBF-EB/M uses an electron beam in vacuum and typically maintains an elevated powder-bed temperature. It is distinct from wire-fed electron-beam directed energy deposition.
Strengths: complex geometry, functional polymer production, dense metal parts, strong aerospace and medical ecosystems.
Constraints: powder safety and genealogy, thermal distortion, supports, surface condition, build size, machine qualification and post-processing.
Binder jetting selectively deposits a liquid binder onto a powder bed. The printed object is usually a weak green part or mold that requires additional processing.
Sand binder jetting: produces molds and cores for metal casting.
Metal binder jetting: prints a green part followed by depowdering, debinding and sintering.
Ceramic binder jetting: creates green ceramic shapes requiring thermal processing or infiltration.
Color model printing: uses colored binder with suitable powder systems for visual models.
Strengths: rapid area-based printing, support-free powder-bed geometry, high nesting density and useful foundry applications.
Constraints: fragile green parts, depowdering, binder removal, furnace capacity, shrinkage, distortion and final density.
Material jetting deposits droplets of build material. The deposited material can be cured by light, cooled from a molten state or processed through another consolidation step.
Photopolymer material jetting: produces detailed multi-material and multi-color polymer models.
Wax jetting: creates precision casting patterns.
Nanoparticle or suspension jetting: deposits material-containing droplets followed by drying, curing or sintering.
Functional ink deposition: overlaps with printed and additively manufactured electronics.
Strengths: fine visual detail, color, controlled droplet placement and multi-material capability.
Constraints: material cost, support removal, UV and thermal aging, nozzle maintenance and limited structural-material options on many platforms.
6. Directed energy deposition
Directed energy deposition delivers material into a focused heat source. Unlike powder bed fusion, feedstock enters only where material is being deposited.
DED route
Energy source
Feedstock
Typical use
Laser DED
Laser
Powder or wire
Repair, coatings and feature addition
Arc DED / WAAM
Electric arc
Wire
Large structures and high-rate near-net deposition
Electron-beam DED
Electron beam
Usually wire
Large reactive-metal preforms under vacuum
Strengths: repair, large build envelope, high deposition rate, hybrid manufacturing and low buy-to-fly potential.
Constraints: coarse feature resolution, thermal distortion, bead stability, substantial machining and difficult inspection of large volumes.
Sheet lamination bonds layers of sheet material and shapes them into the final geometry. Major routes include:
Laminated object manufacturing: cuts and bonds paper, polymer or composite sheets.
Ultrasonic additive manufacturing: bonds metal foils using ultrasonic energy, often with intermediate machining.
Composite sheet lamination: stacks and bonds reinforced sheets or tapes.
Strengths: relatively low thermal exposure in ultrasonic metal routes, embedded sensors or channels, multi-material sheet combinations and rapid model production.
Constraints: interlayer bonding, geometric access, removal of surrounding material, limited adoption and process-specific design rules.
Processes often confused with the seven categories
Term
How to classify it
Hybrid manufacturing
A production system combining AM with machining or another process; the AM step still belongs to one of the seven categories
Bioprinting
An application domain using extrusion, material jetting, vat or other deposition principles
Construction 3D printing
Usually material extrusion, although printed formwork and metal routes can use other categories
Additively manufactured electronics
An application field using material jetting, extrusion, aerosol deposition and hybrid methods
Cold spray additive manufacturing
Commonly treated within directed-energy-deposition-related industrial frameworks, although consolidation occurs through high-velocity solid-state impact rather than melting
Voxel printing
A design and material-control concept rather than a separate fundamental process category
4D printing
Printed objects designed to change over time under a stimulus; not a separate AM process category
How to select the right process
Define the application. Prototype, tool, implant, flight part and visual model require different evidence.
Start with the material. Confirm that a qualified feedstock and post-processing route exist.
Set the geometry envelope. Include build size, minimum walls, channels, overhangs and machining access.
Define property requirements. Strength, fatigue, temperature, chemical resistance and aging may eliminate processes early.
Map post-processing. Supports, cleaning, heat treatment, HIP, debinding, sintering and finishing can determine feasibility.
Plan inspection. Complex internal features need credible measurement and defect-detection methods.
Calculate accepted-part economics. Include yield, labor, furnaces, machining and quality—not only print time.
Evaluate scale. Determine whether takt time and downstream capacity meet demand.
Check qualification maturity. Standards, supplier capability and material data vary by process.
Compare hybrid alternatives. The best solution may print only the difficult feature and use conventional processes elsewhere.
Quick process-selection matrix
Requirement
Processes commonly considered first
Fine polymer detail
Vat photopolymerization or material jetting
Durable support-free polymer production
Polymer powder bed fusion
Complex dense metal parts
Metal powder bed fusion
Large metal near-net shapes
Directed energy deposition
High-density metal batch production
Metal binder jetting where sintering and economics are proven
Low-cost desktop prototypes
Material extrusion
Sand molds and cores
Binder jetting
Multi-color visual models
Material jetting or selected binder-jet systems
Embedded materials or sensors in metal foil
Ultrasonic sheet lamination
Repair or local feature addition
Directed energy deposition
Conclusion
The additive manufacturing universe is easier to understand when commercial names are mapped to seven standardized process categories. Each category solves a different material-delivery and consolidation problem. Process selection should begin with application requirements and include the complete downstream route, qualification burden and cost per accepted part.
Dental additive manufacturing is one of the most mature examples of mass customization. The real advantage comes from connecting patient data, treatment design, printing, washing or sintering, inspection and clinical delivery in a controlled digital workflow.
A dental resin is not approved for every dental use. The exact material, printer, wash, post-cure and intended indication must match the validated device route.
The dental digital workflow
Capture patient geometry: Intraoral scan, desktop scan or conventional impression converted to digital data.
Plan treatment or restoration: Teeth, gingiva, implant position and occlusion are reviewed in dental CAD software.
Design the device: Model, guide, splint, denture, temporary restoration or metal framework is created within approved rules.
Prepare the build: Orientation, supports, nesting, layer strategy and material profile are released.
Print: The device or manufacturing model is produced on a qualified machine.
Post-process: Wash, dry, post-cure, support removal, sintering, polishing or finishing are completed as required.
Inspect: Identity, dimensions, fit, surface and device-specific requirements are verified.
Clinical delivery: The dentist checks fit and use under the applicable treatment plan.
Retain records: Scan, design, material lot, printer, build, post-cure and release data remain linked.
What is actually 3D printed in dentistry?
Application
Typical manufacturing route
Key control
Orthodontic models
Vat photopolymerization followed by washing and curing
Dimensional accuracy and production throughput
Clear aligners
Traditionally thermoformed over printed models; direct printing is an emerging validated route for specific systems
Treatment plan, material indication, thickness and final cure
Surgical guides
Dental resin printing, washing, curing and sterilization
Guide fit, sleeve position and sterilization compatibility
Splints and night guards
Direct resin printing or conventional fabrication from a digital design
Biocompatibility, occlusion, wear and post-cure
Denture bases and teeth
Printed components assembled or printed using device-specific systems
Bonding, fit, fracture resistance and intended-use clearance
Temporary crowns and bridges
Direct printing with indication-specific resin
Marginal fit, cure, strength and intraoral exposure
Permanent restorations
Selected printable resins or ceramics where specifically validated
Long-term wear, color, strength and regulatory status
Metal frameworks
Laser powder bed fusion of cobalt-chromium or titanium, then heat treatment and finishing
Fit, surface, support removal and material properties
Castable patterns
Printed resin pattern followed by investment casting
Burnout behavior and casting accuracy
Anatomical models
Polymer printing from imaging data
Segmentation and dimensional fidelity
Aligner production: model-based vs direct printing
Most established aligner production has used a two-step route: print a sequence of dental models and thermoform polymer sheets over them. This scales well but creates a model for every treatment stage.
Directly printed aligners can remove the model and thermoforming steps, but the route is not simply “print any transparent resin.” It requires a material and process validated for direct intraoral use, controlled thickness, mechanical response, washing, post-curing and treatment performance.
Vat photopolymerization in dental production
Laser SLA, DLP and MSLA systems all cure liquid resin, but their optical architecture, pixel or spot behavior and separation mechanics differ. Dental production should be validated at the system level:
A part leaving a resin printer usually contains uncured surface resin and has not reached its final properties. Inadequate washing or post-curing can affect fit, strength, surface tack, residual chemistry, color and biocompatibility.
Do not mix validated wash and cure parameters between different materials.
Track solvent contamination and replace it using defined limits.
Allow parts to dry before post-curing.
Space devices so light and heat reach all required surfaces.
Verify cure-unit output and maintenance.
Inspect internal channels and guide holes for retained resin.
Use final-condition parts for performance evaluation.
Dental material indications are specific
The FDA notes that dental materials can be cleared for specific intended uses, such as denture bases, retainers, night guards, crowns or bridges. Clearance for one indication does not automatically allow the same material to be used for another device.
Check the current manufacturer instructions and applicable regulatory status for the exact region. Terms such as “dental resin,” “biocompatible” or “medical grade” are not sufficient by themselves.
Metal additive manufacturing in dentistry
Metal powder bed fusion can manufacture cobalt-chromium and titanium frameworks, implant-related components and other dental hardware. The production route can include:
Powder and machine qualification
Support and build-layout control
Stress relief or other thermal processing
Part separation and support removal
Machining of interfaces
Polishing and cleaning
Dimensional and material verification
As-built metal surfaces are not automatically suitable for every oral-contact or fatigue application. Surface and cleaning requirements must be defined for the finished device.
Chairside, dental laboratory or industrial production?
Model
Strength
Operational challenge
Chairside
Fast clinical iteration and fewer logistics steps
Limited staff, quality-system burden and equipment maintenance
Dental laboratory
Specialized design and broad device capability
Order mix, traceability and customer-specific requirements
Centralized industrial production
Automation, scale, validated cells and material expertise
Logistics, turnaround and dependence on digital-data quality
The correct model depends on case volume, device risk, required turnaround, staff competence and the ability to control the complete post-processing route.
Quality-control checklist
Confirm patient and order identity before design and print release.
Validate the scanner, software and design workflow.
Use the approved printer–material–profile combination.
Track resin or powder lot, storage and reuse.
Control orientation, supports and nesting.
Record washing, drying and post-curing.
Inspect fit-critical and guide-critical dimensions.
Verify cleaning and sterilization where required.
Manage failed builds, remakes and nonconformances.
Retain traceability from scan to clinical delivery.
Common misconceptions
“All aligners are directly printed.” Most established production has used printed models and thermoforming.
“Any biocompatible resin can be used intraorally.” Intended use and validated processing are specific.
“Higher pixel resolution guarantees better fit.” Optics, resin, compensation, orientation and post-cure all affect accuracy.
“Printing eliminates dental technicians.” Digital design, finishing, inspection and clinical judgment remain essential.
“Every crown or implant can now be printed.” Material and device maturity vary substantially by application.
Conclusion
Dental AM succeeds because it converts unique patient geometry into a repeatable digital-production system. The competitive advantage is not the printer alone; it is the validated connection between scanning, design, material, post-processing, inspection and clinical use.
