Innovative 3D printing process with toner

Metals and ceramics can also be printed this way

Having managed the challenges of electrophotographic 3D printing with plastics, the two project partners now also aim to explore its use in metal and ceramic production. The basic procedure remains unchanged. However, they face the additional difficulty that the metal particles to be processed are electrically conductive, which complicates the detachment of the particles from the substrate. The permanent connection is therefore achieved in this process by a sintering process, in which the layers are heated under increased pressure. Toner with different materials could be used for the various layers of a product. This makes it conceivable, for example, to print functional electronic components, as is emphasized. Differentially colored ceramic or polymer particles open up new design possibilities.

Space missions with material-flexible spare parts manufacturing

Once the process is mature, it could become an alternative to powder melting additive manufacturing processes in metal production. A particular advantage is that it works independently of gravity and does not cause particles to float in space – therefore, its application in space travel is also conceivable, as the experts note. Thus, with just one device, various spare parts or tools made of polymers, metals, and ceramics could be produced during a mission. Given the very high transport costs to space, the project partners see great potential for application.

More about the project and the future of this approach ...

The now completed project "Development of a novel electrophotographic 3D printing process" was conducted by TH Köln and mz Toner Technologies GmbH & Co. KG from 2021 to 2023 and was supported by the Federal Ministry for Economic Affairs and Climate Action as part of the "Central Innovation Program for SMEs" (ZIM). The two project partners are now collaborating on the two-year project "Development of a novel 3D printing process for metal materials based on electrophotography" (ElPhoMet3D), which is also funded through the ZIM program.

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Date: 08.12.2025

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