JuggerBot 3D Chooses Research Partners for Air Force Large-Format Hybrid Additive Manufacturing Project

JuggerBot 3D, an industrial 3D printer OEM, 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 reliable process parameters for consistent material deposition, demonstrating the steps needed to produce production tooling for composite manufacturing.

This $4-million congressional award was announced in February 2024 and is being funded by the Office of the Under Secretary of Defense for Research and Engineering Manufacturing Technology (OSD(R&E)). The project focus is to advance large-scale hybrid additive manufacturing (AM) in order to enable the production of faster, less expensive tooling which is critical to 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 ft.³, showcasing critical process controls synonymous with JuggerBot 3D’s additive technologies. Throughout the project, which is set to be completed in December 2025, several phases of technology development will occur — from system development to comprehensive modeling and advanced toolpath development.

As the project progresses into system development and validation, JuggerBot 3D says the expertise of ORNL and MSU-ACI is crucial. ORNL is known for advancing innovative AM technologies, including FGF (aka pellet-fed 3D printing), and has been selected to support advanced toolpath Collaborative Research and Development Agreements (CRADAs) generation software. This selection builds on previous CRADAs which focused on sophisticated AM processing, such as JuggerBot 3D’s Bead Characterization System (BCS) and other competencies found in the JuggerBot 3D Material Card.

In an industry first, 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.

MSU-ACI is known for pioneering composite technologies and will lead system-level validation. This process is said to include rigorous material testing and assessment (MT&A) to ensure the effectiveness of the established process parameters for both thermoset and thermoplastic materials.

“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.,” says Hunter Watts, MSU-ACI research engineer. “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.”

While technical development is key, the project’s true value lies in its long-term impact. By accelerating production timelines for limited-life aircraft and reducing costs, this initiative will empower the aerospace and defense sectors to meet evolving demands with unmatched precision. By enhancing manufacturing capabilities, these innovations will support the warfighter at the speed of battle, offering parts designed to withstand high duress. As a result, the technologies developed and the data collected will enable the additive production of medium and large-scale aerospace tools and secondary structural components.