Axtra3D bridges gap between SLA precision and DLP speed in 3D printing – Interview with CSO Rajeev Kulkarni

Axtra3D, a company founded in 2021 and headquartered in Charlotte, NC, with a subsidiary in Vicenza, Italy, has developed a 3D printing technology called Hi-Speed SLA, which is at the core of their flagship product, the Lumia X1. This technology integrates several advanced features, setting new standards for precision and efficiency in additive manufacturing. In an interview with 3Druck.com, Chief Strategy Officer Rajeev Kulkarni shares his insights into the 3D printing industry.

The Lumia X1 is powered by three key technologies: Hybrid PhotoSynthesis (HPS), TruLayer Separation, TruLayer Adaption and a dual Z-axis system. Together, these innovations redefine the capabilities and performance of 3D printers:

HPS combines a laser with a DLP system to simultaneously capture both internal and external structures. The DLP system covers large areas efficiently, while the laser focuses on intricate details and external surfaces, ensuring high resolution. This dual approach enables the Lumia X1 to produce parts with the accuracy of SLA at the speeds typically seen in DLP and LCD technologies.

The innovation of TruLayer Separation facilitates seamless layer transitions by rapidly detaching the active print layer and advancing to the next. It eliminates the hydrostatic forces usually encountered during layer separation in DLP and LCD printers, which shortens wait times and allows for the printing of large, complex parts with a smooth, glass-like surface finish directly from the printer.

TruLayer Adaption ensures the glass plate remains perfectly flat for each layer by dynamically adjusting to maintain the precise resin thickness needed. Unlike the fixed glass plates found in other printers, this dynamic adjustment reduces the need for extended curing times and ensures consistent quality across the entire print platform, regardless of layer height.

These advances are transforming a wide range of applications, with customers using them to produce mould inserts, electrical connectors, dental prostheses, jewellery models, functional automotive parts, medical stents, turbine blades, functional prototypes and more. Its adoption is being driven by the fact that Lumia applications get the best of SLA, DLP and LCD in one system, along with a diverse portfolio of materials from all the leading material suppliers. 

Axtra3D’s advanced solutions have been designed to meet a wide range of industrial and healthcare applications: Axtra Solutions™ for turnkey 3D printing solutions with optimised print profiles, and Axtra OpenAccess™ for flexible experimentation with new materials and applications. The company continues to raise manufacturing standards with expertise in moulds, general prototyping, small to medium production runs and dental models, shaping the development of additive manufacturing through photo-polymerisation.

Interview with Rajeev Kulkarni

In an interview with 3Druck.com, Rajeev Kulkarni, Chief Strategy Officer at Axtra3D, shares his insights into the additive manufacturing industry, focusing on the impacts on industry and healthcare applications. He also identifies the innovations he believes are most relevant to the sector and comments on the effects of crisis and potential future developments.

In your opinion, what is the significance of additive manufacturing for industry and healthcare applications?

Additive manufacturing is driving a shift toward more sustainable, efficient, and personalised production in both industrial and healthcare. Its ability to reduce waste, lower costs, and enhance innovation positions it as a critical technology to complement traditional manufacturing. It helps push the boundaries in design, manufacturing, and patient care.

Within the industrial area, AM enables on-demand production, reducing the need for large inventories and cutting down lead times. This flexibility is crucial for industries like aerospace and automotive, where custom, lightweight, and complex components are essential. AM facilitates the creation of intricate geometries that are often impossible or cost-prohibitive with traditional methods. Moreover, the technology allows for rapid prototyping, which accelerates product development cycles and fosters innovation. The shift toward localised manufacturing using AM also supports supply chain resilience by reducing dependency on distant suppliers, which is increasingly critical in a global market prone to disruptions.

In Healthcare, the main driver is mass customisation. It allows for the creation of patient-specific medical devices, such as implants, prosthetics, and surgical instruments, tailored precisely to individual anatomical needs. This customisation enhances the effectiveness and comfort of medical interventions. AM also plays a pivotal role in digital dentistry where it supports more than fifteen different applications areas and in bioprinting, where living cells are used to fabricate tissues and organs, potentially addressing the critical shortage of donor organs. Its ability to produce complex structures at a micro-scale has opened new avenues in drug delivery systems and regenerative medicine.

Additive manufacturing has developed continuously over the last few years. Which innovations or technological breakthroughs do you consider to be particularly important?

Additive manufacturing (AM) has experienced continuous development, with several key innovations driving its advancement.

Improvement in Functional Polymers: The development of advanced functional polymers offers enhanced mechanical properties, making them suitable for demanding industrial applications, as well as biocompatible polymers critical for medical devices like implants and prosthetics.

Rise of Metal 3D Printing: Metal 3D printing technologies, such as selective laser melting (SLM) and electron beam melting (EBM), have advanced significantly, enabling the production of high-performance metal parts with complex geometries. These innovations are crucial for industries like aerospace, automotive, and medical, where the ability to produce lightweight and durable parts is essential.

Design for Additive Manufacturing (DFaM): It optimises product designs specifically for AM, allowing for the creation of complex, lightweight structures and reducing material usage. This design approach is especially valuable in aerospace and automotive, where weight reduction directly impacts fuel efficiency and cost.

Production Applications: AM has shifted from prototyping to full-scale production, supported by faster, more reliable systems that produce high-quality, repeatable parts. This transition makes AM a viable option for low-to-medium volume manufacturing across various industries.

Large-Scale Additive Manufacturing: Large-scale 3D printing technologies are transforming industries like construction and durable goods by enabling the production of large components or structures on-site, reducing cost.

Advancements in Bioprinting: Bioprinting continues to advance, with the potential to revolutionise regenerative medicine by creating complex tissues and organs, addressing the critical shortage of donor organs.

Enhanced Post-Processing Techniques: Automated post-processing systems streamline finishing processes, improving the overall efficiency and quality of AM parts.

Sustainable and Recyclable Materials: The development of eco-friendly materials and closed-loop recycling systems are pushing AM toward more sustainable manufacturing practices, reducing its environmental impact.

Finally, the integration of AI with AM represents the next frontier in digital manufacturing. AI has the potential to improve print quality, optimise production, and predict defects, leading to more efficient and reliable manufacturing processes. As these innovations converge, AM can lead the true move into digital manufacturing driving more overall efficiency.

First Corona and now high inflation are major challenges for the whole industry. How do you think the multiple crises affect the additive manufacturing industry?

The industry has faced significant challenges in recent years, first with the global disruption caused by the COVID-19 pandemic and now with the pressures of high inflation. These crises have had a profound impact on the industry, affecting everything from supply chains to market adoption.

The pandemic caused widespread disruptions in global supply chains, leading to material shortages, production delays, and increased costs. For the AM industry, which depends on specialised materials like metals and advanced polymers, these disruptions have not only slowed down production but also driven up costs. It has prompted several companies to rethink their sourcing strategies and consider more localised production options.

Economic uncertainty, compounded by inflation, has further strained the industry by delaying investments in new technologies and innovation. Many companies, facing tighter budgets, have scaled back their spending on research and development, as well as on new equipment and Got-To-Market expansion. This reduction in investment threatens to stifle growth.

High inflation has also driven up the costs of raw materials, energy, and logistics, all of which are critical to AM operations. These rising expenses have created pricing pressures, forcing AM companies to either absorb the increased costs—squeezing profit margins—or pass them on to customers, which could dampen demand. In a competitive market, this is a delicate balance to maintain, and it poses significant challenges to sustaining growth.

The economic downturn has led many industries, such as aerospace, automotive, and consumer goods, to cut back on spending, directly affecting the adoption of AM technologies. Companies that had previously been investing in AM for prototyping or production have become more cautious, prioritising essential expenditures over new technology adoption. 

What impact do you think additive manufacturing will have on different industries and possibly society in the coming years?

AM’s ability to produce complex, customised parts on change business models within the successful niches. Within those value areas, it will transform manufacturing, enabling rapid prototyping and reducing the need for large inventories. This shift will enhance efficiency and flexibility, particularly in sectors like aerospace, automotive, and healthcare, where AM can create lightweight components and patient-specific medical devices.

AM’s role in localised production will strengthen supply chain resilience by minimising dependency on global suppliers, which is crucial in times of crisis. In healthcare, advances in bioprinting and personalised medicine could revolutionise treatments and organ transplantation.

Moreover, AM’s potential for sustainable practices — through reduced waste and the use of recyclable materials — aligns with broader environmental goals leading to smarter, more efficient manufacturing processes.

Here you can find further information on Axtra3D.