Multi-material 3D printing platform for electronic sensors and devices

Overview

Morningbird Media Corporation has developed a multi-material fusion deposition modeling (FDM) 3D printer called the Electronic Alchemy eForge, capable of printing up to eight different material filaments simultaneously. The platform uses proprietary mixtures of thermoplastic adhesives combined with select micro and nano powders to create materials with tailored electronic properties. These mixtures enable the 3D printing of functional sensors and devices for biomedical and other applications, including temperature, haptic, chemical, acoustic, and electromagnetic sensing.

Technical specifications

Key features:

• Multi-material FDM 3D printer supporting up to eight simultaneous material filaments
• Proprietary mixture formulas combining thermoplastic adhesives with functional powders such as graphene, semiconductors, magnetic powders, and piezoelectric powders
• Adjustable temperature ranges and curing profiles tailored to each mixture
• Tunable mechanical and electrical properties to match application requirements
• Demonstrated ability to 3D print pressure and temperature sensor matrices, including an insole device for gait and performance measurement in biomedical applications such as diabetes monitoring
• Verified production of the world's first FDM 3D printed diode

Technology readiness level

The Electronic Alchemy eForge has progressed through five prototyping generations and is currently in the design stage for the series 2 commercial device. Material filaments and printed sensors have been developed, tested, and verified in laboratory settings. Future validation efforts will focus on systematically characterizing mechanical properties (shearing, deformation, brittleness, curing), electrical properties (conductivity, capacitance, electron transport, radiating), and thermal properties across different mixture ratios. The team is seeking partners and funding to support software development and analysis, materials sourcing, fabrication and assembly, and personnel to advance toward commercial readiness.