Juggerbot 3D Names Partners for Additive Project

JuggerBot 3D LLC, an industrial 3D printer original equipment manufacturer, has selected key technical partners for a hybrid additive manufacturing (AM) project through the Air Force Research Laboratory (AFRL). Mississippi State University’s Advanced Composites Institute (ACI) and Oak Ridge National Laboratory (ORNL) have been chosen as technical partners for their expertise in Fused Granulate Fabrication (FGF) and Direct Ink Writing (DIW) composite manufacturing.

These organizations will collaborate to develop process parameters for material deposition, demonstrating what's needed to produce production tooling for composite manufacturing.

This $4 million congressional award, funded by the Office of the Under Secretary of Defense for Research and Engineering Manufacturing Technology, aims to advance large-scale hybrid additive manufacturing to enable production of faster, less expensive tooling needed for the defense and aerospace industry.

The project involves the development of a system integrating two-part resin and pellet-fed material extrusion technologies, processing performance-grade thermoplastic polymers and advanced thermoset resin inks, including epoxies and vinyl esters. The system is designed to reach build volumes of 360 ft³, showing process controls synonymous with JuggerBot 3D’s additive technologies. Through the project, set to be completed in December 2025, several phases of technology development will occur, from system development to modeling and advanced tool path development.

As the project progresses into system development and validation, the expertise of ORNL and MSU ACI is crucial. Oak Ridge National Laboratory, known for advancing additive manufacturing technologies, including Fused Granulate Fabrication (AKA pellet-fed 3D printing), has been selected to support advanced tool path generation software. This selection builds on previous Collaborative Research and Development Agreements focused on AM processing, such as JuggerBot 3D’s Bead Characterization System (BCS) and other competencies found in the JuggerBot 3D Material Card. ORNL and JuggerBot 3D will enhance slicing software and printer hardware to process thermosets independently and simultaneously with thermoplastics. As a result, JuggerBot 3D will also develop and integrate thermoset Material Cards.

Mississippi State University’s Advanced Composites Institute will lead system-level validation. This process, which includes material testing and assessment (MT&A), ensures effectiveness of process parameters for  thermoset and thermoplastic materials.

Highlighting the project’s impact, Hunter Watts, research engineer at MSU’s ACI, explains that “In an industry that demands rapid results, transitioning from a six-figure investment in a mold that takes 12-18 months to produce to one that takes only a few weeks at a fraction of the cost is a significant enabler across the U.S.'”

Watts also highlighted the collaborative spirit of the project, notes, “We are excited about the opportunity to partner with JuggerBot 3D and everyone involved to accelerate not only this technology but also the adoption of this groundbreaking manufacturing process.”

Sources: Press materials received from the company and additional information gleaned from the company’s website.