Advanced Materials For Engineering

🪄 3D printing just broke free from gravity — and it happened at Disneyland Paris. Coperni, in collaboration with Disney Research, showcased a revolutionary technique called Rapid Liquid Printing (RLP) — a gel-based 3D printing process that allows objects to form freely in liquid space. The innovation: Instead of building layer by layer, RLP prints directly inside a gel bath. The gel supports the structure as it forms, meaning objects can be “drawn” in mid-air with smooth, continuous motion. What’s new: • No gravity constraints — objects print in all directions. • No supports or post-processing needed — a simple rinse finishes the product. • Compatible with soft materials like silicone and rubber, enabling flexibility and realism. Why it matters: This breakthrough eliminates one of 3D printing’s biggest limitations — the need for support structures. It drastically speeds up production, reduces waste, and enables designs that were previously impossible. → Fashion and luxury design — complex, fluid shapes in textiles and accessories → Architecture and furniture — organic, continuous forms without assembly → Healthcare and robotics — flexible components mimicking natural motion To me, this represents the next era of creation — where 3D printing stops stacking layers and starts shaping ideas in real time. Could this be the moment 3D printing becomes as intuitive as sketching in air? #3DPrinting #Design #Manufacturing #Creativity #FutureOfWork #Engineering #ArtAndTech

𝐓𝐡𝐞 𝐢𝐝𝐞𝐚 𝐨𝐟 𝟑𝐃 𝐩𝐫𝐢𝐧𝐭𝐢𝐧𝐠 𝐡𝐚𝐬 𝐣𝐮𝐬𝐭 𝐛𝐞𝐞𝐧 𝐟𝐥𝐢𝐩𝐩𝐞𝐝 𝐨𝐧 𝐢𝐭𝐬 𝐡𝐞𝐚𝐝. Instead of printing metal, a team of scientists in Switzerland grew it from a gel – and the result is 20x stronger than previous methods. Using a water-based hydrogel as a scaffold, researchers at EPFL (École Polytechnique Fédérale de Lausanne) created complex structures that can be infused with metal salts. After several rounds of soaking and heating, the gel vanishes – leaving behind dense, ultra-strong metal or ceramic. Traditional metal 3D printing often results in porous structures with serious shrinkage. This new method dramatically reduces those flaws, producing durable, precisely shaped components with only 20% shrinkage. It also opens the door to building with a wide range of materials – the same gel template can be used to grow iron, silver, copper, or even advanced composites. The technique could revolutionize how we make complex, high-performance parts for energy systems, biomedical devices, and next-gen electronics. It’s also a shift in mindset: rather than designing around the limits of printing materials, this approach lets researchers build first, and choose the material later. The team is already working on automating the process, aiming to bring this breakthrough into real-world manufacturing. Read the study "𝐻𝑦𝑑𝑟𝑜𝑔𝑒𝑙‐𝐵𝑎𝑠𝑒𝑑 𝑉𝑎𝑡 𝑃ℎ𝑜𝑡𝑜𝑝𝑜𝑙𝑦𝑚𝑒𝑟𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝐶𝑒𝑟𝑎𝑚𝑖𝑐𝑠 𝑎𝑛𝑑 𝑀𝑒𝑡𝑎𝑙𝑠 𝑤𝑖𝑡ℎ 𝐿𝑜𝑤 𝑆ℎ𝑟𝑖𝑛𝑘𝑎𝑔𝑒𝑠 𝑣𝑖𝑎 𝑅𝑒𝑝𝑒𝑎𝑡𝑒𝑑 𝐼𝑛𝑓𝑢𝑠𝑖𝑜𝑛 𝑃𝑟𝑒𝑐𝑖𝑝𝑖𝑡𝑎𝑡𝑖𝑜𝑛." 𝐴𝑑𝑣𝑎𝑛𝑐𝑒𝑑 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠, 2025 https://lnkd.in/eian6kVx

Germany is emerging as a significant player in the global race for critical minerals, with reports highlighting substantial lithium reserves essential for the clean energy transition. Such discoveries could strengthen Europe’s push toward energy independence and technological sustainability. Lithium is a key component in rechargeable batteries used in electric vehicles, smartphones, and renewable energy storage systems. As global demand accelerates, securing reliable domestic sources has become a strategic priority for many nations. Large deposits in Europe, particularly within geothermal brine reservoirs like those in the Upper Rhine Valley, are being explored using environmentally friendly extraction methods. These innovations aim to reduce reliance on imports while minimizing environmental impact. The availability of significant lithium reserves could accelerate the growth of electric mobility and renewable energy infrastructure across the continent. It also supports the European Union’s ambitions to establish a resilient and localized battery supply chain. As the world shifts toward decarbonization, such resource discoveries hold immense economic and geopolitical importance. Strategic investments in sustainable mining and processing technologies will play a crucial role in shaping the future of clean energy. #Lithium #Germany #EnergyTransition #ElectricVehicles #BatteryTechnology

Critical minerals are no longer simply natural resources. They are becoming strategic infrastructure. As industries accelerate investment in AI, advanced manufacturing, electrification, semiconductors, and next-generation technologies, access to critical minerals is emerging as a defining component of long-term competitiveness. Mineral reserves do not automatically translate into economic advantage. Extraction capacity, processing capability, infrastructure, investment, governance, and resilient supply chains all influence how those resources create value. For business leaders, this extends well beyond the mining sector.  Many organizations now operate in industries that depend on supply chains built around materials they neither produce nor directly control. Understanding where critical resources originate—and how those ecosystems evolve—is an essential element of long-term strategy and operational resilience. Competitive advantage is increasingly shaped not only by innovation, but by the ability to secure the capabilities and resources that make innovation possible.

Relatively small amounts of critical minerals underpin trillions of dollars in economic value globally. New IEA analysis highlights growing risks, including export controls, although countries are also taking steps to make supply chains more secure 👉 https://iea.li/4aTpQ33 The geographic concentration of critical mineral supply chains continues to grow, particularly for refining. Rare earths are the exception. The top supplier's share fell from 90% in 2023 to 85% in 2025, showing progress is possible with strong policies. Read more in the International Energy Agency (IEA)’s Global Critical Minerals Outlook 2026 👉 https://iea.li/4bNpwDh While critical mineral projects are being announced & developed across the globe, we see a structural imbalance in diversification efforts. Investment outside the dominant supplier remains concentrated in mining, while efforts to expand refining & downstream capacity lag behind. In a complex geopolitical environment, critical minerals have moved to the forefront of countries’ energy, economic & national security agendas. This is making a difference: public finance commitments more than quadrupled between 2023 and 2025, reaching $65 billion. New IEA analysis also sees a major opportunity to diversify supplies of strategic minor minerals. The investment needed is much smaller than the potential risks of disruption and can be seen as economic insurance. Since #CriticalMinerals account for a small share of final product prices, the cost of diversification could have a limited impact on consumers. For example, critical minerals account for around a quarter of battery cell costs but only about 3% of the price of an average EV. Diversified supply is not only a matter of investment: it also means tackling gaps in technology, equipment & workforce skills. Our new Global Critical Minerals Outlook 2026 includes guidance for policymakers on this & more. Read it in full on our site 👉 https://iea.li/4bNpwDh

The Union Budget’s announcement to develop dedicated rare earth and #criticalmineral corridors across #TamilNadu, #Kerala, #Odisha, and #AndhraPradesh comes at a decisive moment for India and the global economy. This initiative is not merely about mining - it is about strategic autonomy, clean industrial growth, and long-term economic resilience. Today, China controls over 60% of global rare earth mining and nearly 85% of processing capacity, creating significant supply-chain vulnerabilities for clean energy, electric mobility, electronics, defence systems, and advanced manufacturing. In contrast, countries such as the United States, Australia, and the European Union are aggressively building domestic capabilities, strategic reserves, and recycling ecosystems to reduce dependence on concentrated supply sources. Rare earth elements are essential inputs for EV motors, wind turbines, solar technologies, semiconductors, batteries, defence electronics, and medical equipment. As India targets large-scale EV adoption, renewable energy expansion, and domestic semiconductor manufacturing, secure access to critical minerals becomes non-negotiable. The proposed corridors—spanning mining, processing, R&D, and manufacturing create an integrated ecosystem rather than fragmented interventions. Equally important is the opportunity to supplement primary mining with secondary sources. Estimates indicate that India’s e-waste alone could yield nearly 1,300 tonnes of rare earth elements, while mine tailings and industrial waste offer additional recovery potential. Last year’s ₹1,500 crore allocation for extracting critical minerals from waste streams was an important start, but scale, coordination, and regulatory clarity are now essential to unlock meaningful impact. The regulatory framework must evolve accordingly. E-waste Management Rules should clearly classify critical minerals as high-value strategic resources, not residual waste. Extended Producer Responsibility (EPR) frameworks must go beyond compliance and actively incentivise recovery, recycling, and reuse. At the same time, India’s large informal recycling sector—currently operating without safety nets must be formalised through technology transfer, skilling, access to finance, and transition incentives, ensuring both environmental protection and dignified livelihoods. From an economic and urban governance perspective, the implications are significant. Rare earth corridors can catalyse clean manufacturing clusters, generate high-skill employment, and reduce import dependence. Cities and industrial regions will benefit from value-added manufacturing, innovation ecosystems, and circular-economy models that align growth. If executed with coordination and clarity, this initiative can deliver multiple dividends: lower emissions, reduced waste, enhanced competitiveness, skilled job creation, and greater self-reliance.

Every ChatGPT query is a mining operation. Not metaphorically. Physically. Electricity pulled through tons of copper. Transmitted via silver contacts. Cooled by rare earth magnets. Every. Single. Prompt. We talk about "the cloud" like it floats. It doesn't. It's bolted to the earth. And here's what almost no one in business is talking about: AI, EVs, renewables, battery storage, grid electrification, and defence systems are all scaling at the same time — and they're all competing for the same finite pool of critical minerals. The IEA projects lithium demand will grow 5x by 2040. Copper faces a 30% supply shortfall by 2035. S&P Global warns of a 10-million-tonne copper deficit that poses "systemic risk" to global industries. But here's the number that should stop every strategist in their tracks: A new AI model takes months to build. A new copper mine takes up to 29 years. That mismatch is the story no one's paying enough attention to. The leaders I work with think about digital transformation as a software problem. A data problem. A talent problem. It's all of those things. But it's also a geology problem. Technology is geology. And the future belongs to the leaders who understand both. Three questions worth asking at your next strategy session: 1. Which critical minerals does your technology roadmap depend on — and who controls the supply? 2. Is your digital transformation strategy accounting for the physical supply chain underneath it? 3. If a mineral supply shock increased your input costs by 40–50% overnight — what's your plan? Full deep dive in this week's Decoding Tomorrow 👇 — ♻️ Repost if you think more leaders need to see the physical reality behind the digital future. #AI #CriticalMinerals #Leadership #FutureOfWork #Sustainability #NetZero #DigitalTransformation #Innovation #Keynote

Aluminum for stator windings 🥉 ➡️ 🥈– A cost-effective alternative to copper even at the system level? 💲 Due to increasing electrification far beyond mobility applications, as well as the expansion of renewable energy sources such as wind power and the associated electricity grid, global demand for copper – and consequently the price of the material – has risen significantly. This, in turn, is reflected in an ever-increasing proportion of the stator winding material costs within the total EDU BOM costs. Next to the use of alternative winding topologies to reduce the overall material usage, the (partial) substitution of copper with aluminum is also frequently discussed. ⏩ On product side, studies condcuted by Schaeffler/Vitesco Technologies, show that, given aluminum’s poorer electrical and thermal conductivity, (partial) substitution would be feasible, for example, in cost-optimised auxiliary/boost EDUs with limited focus on efficiencies and continuous operation, or in cost-optimised EDUs with a high proportion of high-frequency operation. ⏩ Regarding the process – for example, substitution of copper with aluminum in current U-Hairpin stator production lines – studies by PEM RWTH Aachen University and GROB-WERKE GmbH & Co. KG show that although adjustments to several processes are necessary, feasibility is possible without major show-stoppers [excerpt]: ◾ Adjustment of welding parameters ◾ Modification of tools in pin contact and their coating, partly due to altered wear, abrasion and smearing behaviour ⏩ The crucial question that arises, as always: Is there a (cost) advantage at the overall system level? ◾ The reduced mechanical strength of aluminum may require an adjustment or relaxation of bending radii and angles currently used, meaning that space requirements and material consumption will increase ◾To exploit the favourable AC loss behaviour of aluminum in WLTP relevant operation points, the use of high-quality materials and manufacturing processes for the gearboxes and power electronics are necessary ◾ Does the poorer adhesion of currently common conductor insulation materials to aluminum reduce the cost advantage due to a lower varnishing/ extrusion line speed or fundamentally limits the choice of materials? ⏩ What do you think about replacing copper with aluminum in traction applications❓Might auxiliary systems be a more suitable application❓ Sources♨️: ℹ️ New materials in Hairpin Stators: Challenges for the Production – René S., EPTS 2025, 8th of October 2025 (Karlsruhe) ℹ️ Alternative Solutions for Hair Pin-Stator Windings in terms of an Increase of the Cost-Benefit Ratio – Wilhelm Hackmann, EDPC 2024, 27th of November (Regensburg) ℹ️ Alternative Winding technology to Improve E-Motor Efficiency – Florian Sell-Le Blanc, EV/HEV POWERTRAIN 2026, 26th of February 2026 (Berlin) Achim Kampker | Henrik C. Born | Sebastian Hartmann | Yazan Bajah | Justus Schleicher | Tim Franitza | Moritz Stöckler | Rhesa Edrick Tendean

🚨 The automotive industry is quietly undergoing a significant materials transition Ferrari and BMW Group are introducing new vehicle models with lightweight, cost-effective aluminium wiring, joining Tesla and several Chinese EV manufacturers in reducing their reliance on copper for electrical systems. For more than 200 years, copper has been the industry standard for electrical wiring. Today, rising material costs, the need for lighter vehicles, and advances in aluminium wiring technology are driving a shift toward a viable alternative. 💡 According to JPMorgan, this trend could affect approximately 2% of global copper demand this year. Beyond automotive, manufacturers across industries - including cable and air conditioning - are increasingly adopting aluminium to improve cost efficiency while maintaining performance.

Extracting critical minerals from mine wastewater. (NYTimes.com) Montana's former classic open pit Cu mine, the Berkeley Pit at Butte, is being exploited for critical minerals. The famous Berkeley Pit is now filled with 50 billion gallons of a highly acidic, toxic metalliferous brew. Montana Resources pipes liquid from the pit, enabling it to cascade onto piles of scrap iron. The iron becomes copper and is gathered for production at its Continental Pit mine. Among the other big waterborne prizes in the Berkeley pit next to the town of Butte are two light rare-earth elements, neodymium and praseodymium. They are vital for small, powerful magnets in electric vehicles, for medical technology and for defense purposes, such as precision-guided missiles and satellites. “We’re turning a giant liability into something that’s contributing to defense,” said Mark Thompson, vice president for environmental affairs at Montana Resources. “There’s some high-level metallurgy going on here." Paul Ziemkiewicz, director of the water research institute at West Virginia University, has researched the pit water in Butte for 25 years. He and a team of researchers from Virginia Tech and L3 Process Development, a chemical engineering firm, developed a method to extract critical metals from acid mine drainage in West Virginia’s coal mines, the same process now used in Butte. Large, densely woven plastic bags are filled with a sludge from the treatment plant. The water percolates out, leaving a preconcentrate of about 1% to 2% rare earths that need further refinement, with chemical processes. The final step in the patented process is an extraction with solvents that creates pure rare-earth elements. The Butte project is awaiting word on a Defense Department grant of $75 million to build a concentrator, the last step needed to refine the preconcentrate to rare earths and begin full-scale production. Zinc is also plentiful in the acid-mine-drainage mix here and, because it fetches a higher price, is important as a way to pay for the process. Nickel and cobalt are also extracted. The Berkeley Pit has been a festering sore since 1982, when, the Anaconda Copper Co. closed the open-pit mine, turned off the pumps and let water fill it. The water is so acidic from acid mine drainage that when tens of thousands of snow geese flew over it on their migration in 2016, many landed on the surface and were quickly poisoned. About 3,000 birds died. The Atlantic Richfield Co. and Montana Resources are required to treat the pit water in perpetuity to keep it from reaching levels that could contaminate the area groundwater. https://lnkd.in/gT-JtqAE https://lnkd.in/gQv-4-hr (Berkeley Pit (center) and Yankee Doodle Tailings Pond (upper left); the city of Butte is at lower right. NASA public domain image.)