In a monumental stride towards sustainable electronics manufacturing, MIT’s Advanced Structures and Composites Center (ASCC) has achieved a significant milestone: fully 3D-printed, three-dimensional solenoids. Solenoids, the core of numerous electronic devices, are traditionally manufactured through complex assembly processes, leading to inefficiencies and limitations in design and performance.

MIT’s approach revolutionizes this process by leveraging multimaterial 3D printing technology, enabling the seamless production of solenoids in one step. Unlike conventional methods, which rely on post-assembly processes prone to defects, MIT’s customized 3D printer delivers superior performance and durability. By incorporating higher-performing materials, MIT’s solenoids exhibit twice the current capacity and three times the magnetic field strength compared to their counterparts.

Beyond cost reduction and waste elimination, MIT’s innovation holds profound implications for space exploration. The ability to fabricate electronic components on-demand using 3D printing technology could revolutionize space missions by circumventing the need for costly and time-consuming part replacements. This democratization of electronics manufacturing aligns with MIT’s vision of empowering global communities with accessible, locally produced hardware.

The modified 3D printer, equipped with four nozzles for precise material deposition, represents a significant leap forward in additive manufacturing capabilities. MIT’s researchers have paved the way for enhanced performance and scalability in 3D-printed electronics by overcoming technical challenges associated with material compatibility and temperature control. Moving forward, MIT’s team aims further to optimize solenoid performance through material innovation and process refinement. With continued advancements, 3D-printed solenoids could revolutionize a wide range of applications, from power converters to soft robotics.

Velásquez-García emphasizes the potential of additive manufacturing to democratize technology, advocating for decentralized production. Teaming up with lead author Jorge Cañada and mechanical engineering graduate student Hyeonseok Kim, their paper on 3D-printed solenoids in Virtual and Physical Prototyping underscores this vision. By enabling local fabrication rather than global distribution, additive manufacturing empowers communities worldwide to create their hardware. This shift not only reduces logistical complexities but also fosters innovation and self-sufficiency in remote areas. Together, they envision a future where technology transcends geographical barriers, driven by the accessibility and versatility of additive manufacturing.

MIT’s groundbreaking research, supported by Empiriko Corporation and La Caixa Foundation, heralds a new era of sustainable electronics manufacturing. By harnessing the power of additive manufacturing, MIT drives innovation towards a more accessible, environmentally friendly future for electronics production.