At the 2025 International Rubber and Plastics Exhibition (CHINAPLAS 2025), new materials for 3D printing became one of the focal points, with several companies showcasing innovative solutions that promote the application of additive manufacturing in industries such as automotive, medical, and consumer goods. Below are the new advancements in 3D printing technology and materials presented by various companies at CHINAPLAS 2025.
BASF introduced a new bio-based TPU (thermoplastic polyurethane) made from renewable resources (such as corn starch), suitable for flexible wearable devices and shoe material 3D printing, with a 50% reduction in carbon emissions. They also showcased the Ultrafuse® high-performance engineering plastics series, including chemical-resistant PA6/GF (glass fiber reinforced nylon) and flame-retardant ASA. BASF collaborated with BigRep to develop large-scale FFF (Fused Filament Fabrication) printing solutions for rapid prototyping of automotive interior components.
eSUN showcased several innovative achievements, focusing on upgrades in eco-friendly materials, breakthroughs in medical applications, and industrial solutions. The new generation of bio-based PLA+ series includes: ePLA-HighStrength, with tensile strength increased to 80MPa (50% higher than traditional PLA), suitable for functional part printing, such as drone frames; ePLA-Flex, a flexible PLA (with a 300% elongation at break), can replace TPU for insoles and wearable devices; carbon-neutral certification: the entire PLA series has passed ISCC PLUS certification, with a 60% reduction in carbon footprint; ePHA (polyhydroxyalkanoate): developed in collaboration with Tsinghua University, achieving a 90% degradation rate in seawater within six months, aimed at replacing plastics used in fishing gear and marine monitoring equipment. eResin-Medical, a light-curing resin, passed ISO 10993 biocompatibility testing and can be used for dental guides and surgical positioning devices; ePLA-Implant: β-tricalcium phosphate reinforced PLA supports FFF printing of scaffolds for bone defect repair, which has entered preclinical trials. ePLA-Ag (silver-loaded PLA) shows >99% antibacterial activity against E. coli and Staphylococcus aureus, suitable for hospital consumables (such as instrument handles). They launched the eCycle system, allowing users to return discarded PLA filaments for chemical depolymerization and regeneration into new filaments (85% closed-loop recycling rate). In collaboration with BYD, they used ePA-CF (carbon fiber nylon) to print electric vehicle battery brackets, reducing weight by 25%. They also partnered with Xiaomi’s ecological chain companies to use ePLA-Pro (high-precision PLA) for printing headphone casings, achieving a surface roughness of Ra<5μm.
DuPont released high-temperature polyamide (PA) materials that can withstand temperatures above 300°C, suitable for aerospace engine components. They introduced conductive TPU for flexible electronic sensor printing. DuPont collaborated with EOS to optimize SLS (Selective Laser Sintering) process parameters to improve material utilization.
Solvay launched PEKK (polyether ketone ketone) high-performance materials, which have strength close to that of metals, suitable for aerospace and medical implants. Carbon fiber reinforced PEEK is suitable for lightweight automotive structural components. Solvay showcased SLS optimization solutions to improve the surface finish of printed parts.
HP introduced the third generation of the Multi Jet Fusion (MJF) system, with a 20% increase in printing speed and support for finer details (50-micron resolution). In collaboration with BMW, they showcased automotive seat brackets printed from recycled carbon fiber reinforced nylon (PA12-CF), reducing weight by 30%. They also added flame-retardant PA11 (bio-based), suitable for electrical enclosures.
Covestro released a new series of light-curing resins (DLP/SLA), including high-toughness resins and transparent medical-grade materials. They collaborated with Carbon to develop recyclable photopolymers suitable for consumer product packaging. AI was used to accelerate material development, shortening the testing cycle for new formulations to just a few days.
The Institute of Chemistry, Chinese Academy of Sciences, introduced temperature-controlled deformable PLA composites for 4D printing of medical scaffolds (automatically expanding at body temperature); nano-ceramic reinforced PLA, enhancing mechanical strength and heat resistance. They developed a multi-material mixing extrusion system to support integrated printing of soft and hard materials.
Germany’s RepRap launched a waste plastic recycling filament extruder that can directly convert PET bottles and packaging waste into 3D printing filament. They showcased 100% recycled PETG filament, suitable for low-cost prototyping.
Materialise released a cloud-based digital material library, integrating data from over 500 types of 3D printing materials worldwide, supporting intelligent material selection. They showcased AI-driven printing process optimization software that reduces waste of support materials.
Active4D (a MIT spin-off) introduced light-responsive self-healing polymers that can automatically repair themselves when damaged through UV exposure. They developed 4D printed smart structures for deformable robotic components.
Avantium (Netherlands) launched 100% bio-based biodegradable PEF filament, which naturally degrades within six months, replacing petroleum-based PLA.
In summary, the trends in 3D printing for 2025 are as follows: (1) Material innovation: bio-based, biodegradable, and high-performance engineering plastics are becoming mainstream; (2) Technology upgrades: AI optimization, 4D printing, and waste recycling technologies are gaining attention; (3) Application expansion: the automotive, aerospace, and medical fields are accelerating the adoption of 3D printing.
(This article was provided by Hu Jing)Typesetting: Zhao RuiwenReview: Diao Xiaoqian
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The Degradable Plastics Professional Committee of the China Plastics Processing Industry Association (referred to as the DPC) is an industry organization voluntarily formed by research institutions, production enterprises, and users engaged in degradable plastics, additives, products, machinery, and instruments. It is a service-oriented, public welfare, self-regulatory, and non-profit organization.
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