Top 10 AM software stories of 2025
RECODE.AM #30
On June 4, 2025 - exactly thirty weeks ago - I published the very first article in the RECODE.AM series.
This series, dedicated entirely to software in 3D printing, was conceived with two goals in mind:
on the one hand, to document the latest achievements of companies operating in this space;
on the other, to explore and anticipate the future directions of software-driven development in additive manufacturing.
Over the course of six months and 29 articles, I covered topics spanning all major additive technologies - from filament-based systems to advanced based on metal powders. I explored the role of AI and its real impact on additive manufacturing workflows, and I also tested several AI-powered applications designed specifically for this industry.
In the end, I think it turned out quite well. The articles have been widely read and actively discussed, and some were even organically shared by readers on LinkedIn - which I truly appreciate. Thank you for that.
As I’ve been saying for a long time: software is what will ultimately move 3D printing from rapid prototyping into true industrial production.
And this transition is already underway.
Companies like Dyndrite - the main partner of both this newsletter and the RECODE.AM series - are clearly leading the way.
Below, you’ll find a list of the 10 most-read articles from the first six months of series. I hope the coming year brings even more topics that are just as engaging.
#10 - How to build a modern material database for 3D printing
Digital 3D material libraries are designed to automatically assign ideal printing parameters to a selected filament. However, the main challenge in creating them is the so-called Digital-Physical Gap - the divide between digital data and the real, variable physical properties of materials, which depend on production batches, storage conditions, and the equipment used.
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#9 - AI-driven 3D printer farms – hype vs. reality
A 3D printer “giga farm” relies on many low-cost FFF machines but requires significant human labor for operation and oversight. AI promises to automate this through smart task scheduling, real-time error detection via sensors, and automatic part handling. However, the economic viability is unclear. While AI can reduce downtime and waste, it cannot solve core mechanical issues of printing, and the high costs for automated hardware and specialized software may outweigh the benefits for many users.
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#8 - The Black Box Problem: why closed AM software blocks the path to Rapid Manufacturing
For over a decade, AM software has been a major barrier to industrial serial production. Designed for prototyping, it remained a “black box” with opaque, unauditable algorithms, hindering process trust and regulatory compliance in high-risk sectors like aerospace or medicine.
The lack of transparency prevented integration with other systems and stifled innovation. The solution lies in adopting open, modular architectures with full API access. This enables traceable, reproducible workflows and seamless digital integration, which are essential for true industrial adoption.
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#7 - Bambu Studio enables the use of different filaments within a single print job
Bambu Studio 2.4.0 introduced a new feature in its Developer Mode: the ability to assign different filaments to specific features of a single object. This means you can now use expensive materials only for visible walls or critical infill, while filling the interior with cheaper filament. This enables significant cost savings and the ability to engineer parts with optimized, multi-material mechanical properties in a single print.
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#6 - Split3r – a super smart solution for large-scale 3D printing
Split3r is a software that solves the core limitation of desktop FFF printing: small build volumes. It intelligently splits large 3D models into printable sections for standard printers. It automatically adds smart alignment joints and pins, labels parts, and provides an exploded view for easy assembly. This approach transforms a farm of affordable printers into a powerful production line for large-scale objects like furniture, cosplay props, or car parts, bypassing the need for expensive, niche large-format machines.
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#5 - Dyndrite integrates with EOS Open Architecture, enabling full toolpath control and 3x higher productivity
Dyndrite, EOS, and nLIGHT have partnered to revolutionize metal 3D printing. By integrating Dyndrite’s LPBF Pro software with EOS’s open printers and nLIGHT’s dynamic AFX lasers, engineers were given unprecedented control over parameters like laser power and toolpaths. This combination has already doubled print speed for customers like Ursa Major while maintaining quality, reducing waste, and accelerating process qualification.
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#4 - I tested PrintU from Bambu Lab - an AI tool for quickly creating 3D-printed bobbleheads from photos
Bambu Lab introduced MakerLab PrintU, a web-based tool designed to quickly turn a photo into a printable figurine. It worked by offering stylized interpretations (like bobbleheads) rather than complex reconstructions. The process involved uploading a photo, selecting a style and pose, previewing a 2D image, and then generating a multi-color 3D model for export and printing.
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I tested PrintU from Bambu Lab - an AI tool for quickly creating 3D-printed bobbleheads from photos
#3 - The metal binder jetting fiasco – and can better software fix it?
Following Desktop Metal’s bankruptcy, the future of its flagship metal binder jetting (MBJ) technology became uncertain. This method, which binds metal powder layers with liquid binder before sintering, faced significant challenges despite its speed and material flexibility. The primary issue was unpredictable, high shrinkage during sintering, leading to dimensional inaccuracy and unreliable part quality. Crucially, software emerged as the key to solving this, needing to predict and compensate for complex thermomechanical deformations. Without advanced, AI-driven simulation and control software, industrial-scale adoption of MBJ seemed unlikely.
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#2 - Bambu Lab closes the security debate
Bambu Lab faced significant criticism and skepticism over its data security and privacy practices, particularly regarding its cloud-based systems. In response, the company underwent a major transformation and launched a comprehensive “Trust Center.” This platform provided full transparency, detailing security measures across hardware, software, and cloud infrastructure. It was backed by independent certifications like ISO/IEC 27001 and 27701.
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#1 - Bambu Lab integrates Helio Additive’s sophisticated simulation tool
Bambu Lab and Helio Additive announced a partnership that integrated the industrial-grade Dragon simulation engine directly into BambuStudio. This allowed users of H- and X-series printers to perform thermal simulations of their prints without leaving the slicer. The voxel-based engine predicted heat exchange, identified risks like poor layer adhesion or deformation, and provided a visual “Thermal Index” with optimization suggestions.
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