Robocasting Research Articles

Progress in Additive Manufacturing of High-Entropy Alloys

High-entropy alloys (HEAs) have drawn substantial attention on account of their outstanding properties. Additive manufacturing (AM), which has emerged as a successful approach for fabricating metallic materials, allows for the production of complex components based on three-dimensional (3D) computer-aided design (CAD) models. This paper reviews the advancements in the AM of HEAs, encompassing a variety of AM techniques, including selective laser melting (SLM), selective laser sintering (SLS), selective electron beam melting (SEBM), directed energy deposition (DED), binder jetting (BJT), direct ink writing (DIW), and additive friction stir deposition (AFSD). Additionally, the study discusses the powders and wires utilized in AM, the post-processing of AM-processed HEAs, as well as the mechanical and corrosion properties of these alloys. The unique ultra-fine and non-equilibrium microstructures achieved through AM result in superior mechanical properties of HEAs, like improved strength and ductility. However, research regarding certain aspects of HEA AM, such as fatigue properties and creep deformation behavior, is still relatively scarce. Future research should focus on overcoming the existing limitations and exploring the potential of HEAs in various applications.

3D-Printed Lithium-Ion Battery Electrodes: A Brief Review of Three Key Fabrication Techniques

In recent years, 3D printing has emerged as a promising technology in energy storage, particularly for the fabrication of Li-ion battery electrodes. This innovative manufacturing method offers significant material composition and electrode structure flexibility, enabling more complex and efficient designs. While traditional Li-ion battery fabrication methods are well-established, 3D printing opens up new possibilities for enhancing battery performance by allowing for tailored geometries, efficient material usage, and integrating multifunctional components. This article examines three key 3D printing methods for fabricating Li-ion battery electrodes: (1) material extrusion (ME), which encompasses two subcategories—fused deposition modeling (FDM), also referred to as fused filament fabrication (FFF), and direct ink writing (DIW); (2) material jetting (MJ), including inkjet printing (IJP) and aerosol jet printing (AJP) methods; and (3) vat photopolymerization (VAT-P), which includes the stereolithographic apparatus (SLA) subcategory. These methods have been applied in fabricating substrates, thin-film electrodes, and electrolytes for half-cell and full-cell Li-ion batteries. This discussion focuses on their strengths, limitations, and potential advancements for energy storage applications.

Colloidal route towards sodium ionic conductor (NASICON) 3D complex solid electrolyte structures fabricated by Direct Ink Writing (DIW)

Progressing towards a sustainable energy model, safer new generation high-performance energy storage devices with large energy density and power are needed. In this sense, the improvement in terms of efficiency and sustainability has led to the interest in solid-state batteries (SSBs). Lately, sodium-ion batteries (SIBs) have become an emerging alternative due to the abundance of raw materials, low cost, and improvements in terms of fast sodium-ion conductor solid electrolytes (SCSEs). Among all the SCSEs, the sodium superionic conductor (NASICON) type electrolyte is one of the most well-known electrolytes, being widely developed in terms of synthesis and materials. However, the processing and manufacturing of these electrolytes have gone almost unnoticed, without considering that well-designed structures of electrodes/electrolytes are the bridge toward turning advanced energy materials into high-performance devices. This work presents the fabrication of 3D complex structures based on NASICON sodium solid electrolytes, obtained for the first time by direct ink writing (DIW). Through a colloidal route, fine NASICON phase powder with high pureness was prepared, enabling the manufacturing of intricate NASICON-printed electrolytes in a one-step fabrication process. By optimizing the ink, a dense electrolyte layer, acting as an ionic conductor and separator, was inserted between two complex porous pattern layers obtaining a device with a total height below 1.15 mm. Further, the densification of the 3D electrolyte was enhanced, reaching high ionic conductivities at room temperature (3.10-4 S·cm-1). Thus, a high-performance sodium ion conductor NASICON solid electrolyte with shorter diffusion pathways and larger interfacial surface areas between electrode/electrolyte was obtained, improving the overall electrochemical performance of the device by a 3D layer-by-layer design.

Drop-on-Demand 3D Printing of Programable Magnetic Composites for Soft Robotics

Soft robotics have become increasingly popular as a versatile alternative to traditional robotics. Magnetic composite materials, which respond to external magnetic fields, have attracted significant interest in this field due to their programmable two-way actuation and shape-morphing capabilities. Additive manufacturing (AM), also known as 3D printing, allows for the incorporation of different functional composite materials to create active components for soft robotic systems. However, current AM methods have limitations, especially when it comes to printing smart composite materials with high functional material content. This is a key requirement for enhancing responsiveness to external stimuli. Commonly used AM methods for smart magnetic composites, such as direct ink writing (DIW), confront challenges in achieving discontinuous printing, and enabling multi-material control at the voxel level, while some AM techniques are not suitable for producing composite materials. To address these limitations, we employed high-viscosity drop-on-demand (DoD) jetting and developed versatile programmable magnetic composites filled with micron-sized hard magnetic particles. This method bridges the gap between conventional ink-jetting and DIW, which require inks with viscosities at opposite ends of the spectrum. This high-viscosity DoD jetting enables continuous, discontinuous, and non-contact printing, making it a versatile and effective method for printing functional magnetic composites even with micron-sized fillers. Furthermore, we demonstrated stable magnetic domain programming and two-way shape-morphing actuations of printed structures for soft robotics. In summary, our work highlights high-viscosity DoD jetting as a promising method for printing functional magnetic composites and other similar materials for a wide range of applications.

Free radical-initiated direct ink writing of liquid polycarbosilane slurry and its conversion into SiC ceramic parts with low shrinkage

Additive manufacturing technology is being developed for manufacturing SiC ceramic parts with designed shape and microstructure. In this study, direct ink writing (DIW) was adopted to print SiC ceramic parts. To avoid incorporating volatile organic solvents or water, a SiC ceramic precursor liquid polycarbosilane (LPCS) was used as the binder of SiC powder and the rheological adjustment additive. The content of LPCS with the content and diameter of SiC powder were optimized to improve the fluidity of slurry, increase its ceramic yield and reduce its shrinkage during pyrolysis. According to the results of rheological analysis and shrinkage during pyrolysis, 78 wt% SiC powders composed of 40 nm SiC powder and 5 μm SiC powder in a ratio of 1:6 was appropriate. For achieving rapid solidification rate of the slurry at low temperature, a free‐radical initiator which can trigger the crosslinking of allyl group on LPCS was incorporated. According to the results of rheology, DSC and FT-IR, the preferred platform temperature for fast curing of DIW slurry was 150 °C. As the slurry accumulated layer by layer on heating platform, the cured green bodies were successfully prepared. After pyrolysis to 1200 °C, SiC ceramic parts were obtained with only 4.43% linear shrinkage associated with the precursor-to-ceramic conversion. Because the shrinkage was limited, no obvious deformation or crack was found.

Additive Fabrication of Polyaniline and Carbon-Based Composites for Energy Storage

The growing demand for efficient energy storage systems, particularly in portable electronics and electric vehicles, has led to increased interest in supercapacitors, which offer high power density, rapid charge/discharge rates, and long cycle life. However, improving their energy density without compromising performance remains a challenge. In this study, we developed novel 3D-printed reduced graphene oxide (rGO) electrodes coated with polyaniline (PANI) to enhance their electrochemical properties. The rGO 3D-printed electrodes were fabricated using direct ink writing (DIW), which allowed precise control over thickness, ranging from 4 to 24 layers. A unique ink formulation was optimized for the printing process, consisting of rGO, cellulose acetate (CA) as a binder, and acetone as a solvent. The PANI coating was applied via chemical oxidative polymerization (COP) with up to five deposition cycles. Electrochemical testing, including cyclic voltammetry (CV), galvanostatic charge/discharge (GCD), and electrochemical impedance spectroscopy (EIS), revealed that 12-layer electrodes with three PANI deposition cycles achieved the highest areal capacitance of 84.32 mF/cm2. While thicker electrodes (16 layers and beyond) experienced diminished performance due to ion diffusion limitations, the composite electrodes demonstrated excellent cycling stability, retaining over 80% of their initial capacitance after 1500 cycles. This work demonstrates the potential of 3D-printed PANI/rGO electrodes for scalable, high-performance supercapacitors with customizable architectures.

Characterization of Direct Ink Writing carbon fiber composite structures with serial sectioning and DREAM.3D

Direct Ink Writing (DIW) combines the flexibility of 3D printing with increased material applications such as thermoset carbon fiber composites, ceramic composites, and metals. The usefulness of direct ink writing, like many additive manufacturing (AM) processes, remains limited for reasons ranging from quality control to lack of process parameter optimization. This study looks to introduce a methodology for characterizing direct ink written carbon fiber composites to facilitate exploration into the relationships between process parameters and material structure. The presented study utilized nine 3D specimens of direct ink writing carbon fiber composites printed with varying process parameters – speed differential, layer height, step-over distance, and nozzle diameter – as the data set. The data was collected with an automatic serial sectioning system, LEROY, from the Air Force Research Laboratory. The collected data was processed in DREAM.3D and analyzed with statistical comparisons of 2D orientation distributions of the fibers, 2D size distributions of the voids, and 2D shape distributions of the voids.

Self-polarized cellulose nanofiber-reinforced PVDF-based piezoelectric composites via direct-ink-writing 3D printing for pressure sensing and energy harvesting

With their unique physicochemical properties, PVDF-based piezoelectric materials demonstrate significant potential in various fields. Nevertheless, their benign piezoelectric performance is usually obtained through polarization post-treatment after material formation. In this study, a self-polarized direct-ink-writing (DIW) 3D printing strategy is proposed for one-step fabrication of high-performance PVDF/cellulose nanofiber (CNF) piezoelectric composites with low energy consumption. Under the synergistic effects of shear/stretching from DIW and hydrogen bonding between PVDF and CNF, α-phase PVDF undergoes gauche-trans conformational transformation into β phase. And then β-phase PVDF is dragged by high aspect ratio CNF into bead-like small crystals to form a multilayered oriented structure, resulting in abundant oriented dipole moments. PVDF/CNF composites with different weight ratios are printed using this strategy, and the results show that the composite film with 5 wt% CNF content exhibits the best piezoelectric performance. Without additional polarization treatment, it achieves a sensitivity of 103 mV/N, 2.2 times higher than conventional cast films. The composite also demonstrates good linear response and durability, meeting the requirements for human motion monitoring and mechanical energy harvesting. This work has opened up new avenues for the efficient and low-energy fabrication of flexible wearable and energy-harvesting devices.

Direct Ink Writing of Rigid Microparticles.

Direct ink writing (DIW) enables 3D printing of macroscopic objects with well-defined structures and compositions that controllably change over length scales of order 100 µm. Unfortunately, only a limited number of materials can be processed through DIW because it imparts stringent rheological requirements on inks. This limitation can be overcome for soft materials, if they are formulated as microparticles that, if jammed, fulfill the rheological requirements to be printed. By contrast, densely packed rigid microparticles with stiffnesses exceeding 2 MPa do not exhibit appropriate rheological properties that enable DIW. Here, an ink composed of up to 60 vol% rigid microparticles with core stiffnesses up to 50 MPa is introduced. To achieve this goal, rigid microparticles possessing soft hydrogel shells are produced. The 3D printed fragile granular structure is transformed into a load-bearing granular material through the formation of a 2nd network within the soft shells and in the interstitial spaces. The potential of these particles is demonstrated to be printed into intricate 3D structures, such as a trophy cup, or cast into flexible macroscopic photonic films.

4D printing of pH-responsive bilayer with programmable shape-shifting behaviour

4D printing of smart materials has seen remarkable advancements in the domain of biomedical devices, with a particular focus on developing responsive and adaptive programmable structures. In this work, we report the 4D printing of two solvent-responsive hydrogels forming a bilayer that undergoes bidirectional actuation depending on the pH of the solvent. A strong interlayer adhesion between the hydrogels is formed without subjecting either of their surfaces to any chemical modification. These hydrogels have an interfacial toughness of 71.8 J/m2 and undergoes no delamination during actuation inside a solvent. Conventionally, pH-responsive actuators are only limited to simple 2D films prepared by solvent casting. However, our work focuses on the design and fabrication of complex bilayer and patterned structures using Direct-Ink Writing (DIW) approach. These printed structures actuate upon immersion in a solvent medium, and the actuation is reversible in nature. The influence of programmable variables on the morphed structure was studied systematically by modifying the rheological properties (in the range of 102−105 Pa.s) and printing parameters (optimized at a printing speed of 5mm/sec, with the extrusion pressure of 5−6 bar and nozzle diameter of 0.5 mm) of the 3D printed bilayer structure. The physicochemical properties of the printable hydrogel ink were tuned such that the same structure can respond to both acidic and basic pH (with non-morphing point at pH 7), by altering the directionality of actuation. We have demonstrated the applications of these pH-responsive actuators in smart valves.

Selective Deposition and Fusion of AISI 316L: An Additive Manufacturing Process for Space Environments via Direct Ink Writing and Laser Processing

Abstract Unlocking the potential of additive manufacturing (AM) for space exploration hinges on overcoming key challenges, notably the ability to manufacture or repair parts on-site during exploration missions with consideration of quality, feedstock utilization, and challenges involved in microgravity environments. While there are multiple efforts to investigate the use of existing metal AM processes such as powder bed fusion (PBF), directed energy deposition (DED), and filament-based material extrusion, each process comes with a different set of challenges in space environments. Here, we introduce a new AM method that integrates the benefits of Direct Ink Writing (DIW) to selectively deposit metallic pastes with laser-based processing to locally de-bind and subsequently melt and fuse metal powder, layer by layer, enabling the manufacturing of AISI 316L samples with densities exceeding 99.0%. The impact of process parameters on single-track dimensions, surface morphology, and porosity was characterized. The efficacy of laser de-binding was assessed via secondary-ion mass spectrometry, permitting the carbon content to be estimated at 0.0152%, which is safely below the acceptable limit (0.03 wt%) for AISI 316L.

Freezing‐Assisted Direct Ink Writing of Customized Polyimide Aerogels with Controllable Micro‐ and Macro‐ Structures for Thermal Insulation

AbstractPolyimide (PI) aerogels have attracted attention in thermal management due to their low thermal conductivity, high porosity, and robust mechanical properties. However, building PI aerogels with elaborately tailored micro‐ and macro‐ structures for optimized thermal insulation performance in specific scenarios remains a challenge. Here, a scalable approach is reported to prepare PI aerogels with controllable micro‐ and macro‐ structures by freezing‐assisted direct ink writing (FADIW) of poly(amic acid) (PAA) inks. This FADIW strategy can enable continuous ink deposition and transient low‐temperature‐induced gelation, contributing to the facile construction of spatially free geometries with structural complexity and shape fidelity. Importantly, controllable construction of microstructures of the aerogels is achieved by controlling the extrusion substrate temperature. The resulting customized PI aerogels show good thermal insulation owing to the porous microstructure and customized macrostructure, enabling good thermal management for portable electronics. In addition, this FADIW strategy is universal and allows for multi‐material integration, broadening the functionality of PI aerogels. Significantly, such FADIW approach can be promisingly applied to realize on‐demand design of PI aerogels and other polymer aerogels with targeted micro‐ and macro‐structures, offering an alternative avenue for the manufacture of customized aerogels toward widespread applications.

Effect of SiC content on the process and properties of PDMS/SiC composites by direct ink writing

Direct ink writing (DIW) has demonstrated great potential due to its convenience and effectiveness in the manufacturing of soft wearable devices. However, commonly used pure elastomer inks exhibit poor preservation characteristics and their thermal conductive properties require improvement. Considering this, a novel composite SiC ceramic ink with added polydimethylsiloxane (PDMS) was developed in this work. Subsequently, the impact of different SiC nanoparticle contents on the rheological, thermal, tensile, and tribological properties of the PDMS/SiC composites were investigated. The results showed that adding more SiC improved the viscosity of the samples, resulting in notable shear thinning behavior; this property proved to be conducive to the printing process. By printing the materials in the longitudinal and transverse directions, pure PDMS showed anisotropic tensile properties, while SiC addition resulted in isotropic properties. PDMS with an addition of 15 wt% SiC showed the greatest elongation at break (up to 120 %), and the samples exhibited better thermal conductivity with greater amounts of added SiC. Adding 5 wt% and 10 wt% SiC to PDMS reduces the coefficient of friction (COF), while 15 wt% SiC content results in the same COF as pure PDMS. These findings proved that PDMS/SiC could be a suitable printing material for future development, such as in the soft wearable electrics field of DIW.

Direct Ink Writing and Rapid Microwave Sintering of Alumina

The additive manufacturing of ceramics is gaining attention due to difficulties in fabricating complex ceramic parts because of its hard and brittle nature. Direct ink writing (DIW) is a unique process in which solid-loaded slurry is extruded to print complex-shaped ceramic parts directly. In the present work, a new composition of high-solid loaded (76 wt.%) alumina ink is prepared for printing ceramic parts with complex structures. The rheology of ink is optimized to ensure the shear thinning behavior of the ink, while thermogravimetric analysis (TGA) of the printed part was carried out to optimize the debinding temperature. The printed alumina part is sintered using the conventional furnace and rapid microwave sintering process, and a comparison has been made. Microwave, a rapid sintering method with a high heating rate, produced >97% dense specimen, while the hardness and flexural strength values of 15.18 ± 0.6 GPa and 148.87 ± 2.14 MPa were achieved, respectively. Rapid microwave sintering of additively manufactured ceramic parts can reduce the energy consumption and overall production time needed to manufacture ceramic parts.

4D Printing of High-Performance Shape Memory Polymer with Double Covalent Adaptive Networks

Achieving 4D printing of shape memory polymers with both high strength and high transition temperature remains challenging due to the inherent incompatibility between the rigid molecular structure required for high strength and the molecular structure that moves on demand necessary for the shape memory effect, the limitations of high-performance polymer reaction kinetics, as well as internal stress during the printing process. Here, a direct ink writing (DIW) printed high-precision cyanate ester-urethane (CU) shape memory polymer with excellent performance was accomplished by incorporating two dynamic covalent bonds (carbamate and cyanuric acid) through copolymerizing cyanate ester with polyurethane acrylates. During curing, carbamate and cyanuric acid enable stress relaxation and polymer network rearrangement, facilitating the permanent reconfiguration of CU to form a novel triazine network structure. As a result, a high mechanical properties CU with excellent strength (83 MPa) and superior Young's modulus (2.37GPa) were obtained, besides, the transition temperature (near 250 oC) is the highest in comparison to currently reported 4D-printed shape memory polymers. Furthermore, this reconfigurability was demonstrated by imprinting various surface patterns at microscopic level. Moreover, the reconfigurability of CU provides a novel strategy for smart molds in deformation and easy demolding. Overall, this study opens up a new avenue for the development of high-performance 4D printed shape memory polymers.

3D printing of porous ceramic scaffold based halloysite clay for efficient seawater desalination

Solar driven interfacial evaporation is an efficient and environmentally friendly method to achieve sustainable desalination and address the long-term freshwater shortage crisis. Here, a polydopamine (PDA) coated porous ceramic scaffold (PCS) based on halloysite clay nanotubes (HNTs) is developed as a solar interfacial evaporator for efficient seawater desalination. The PCS is prepared by direct ink writing (DIW) 3D printing technology, in which the ink is composed of HNTs (67 %), sodium silicate (0.2 %) and polyethylene glycol (3.7 %). The PCS has excellent compressive strength, corrosion resistance and chemical stability. PDA coating enhances the hydrophilicity of the scaffold, which can promote water replenishment on the evaporation surface and achieve effective anti-salt seawater desalination. The PDA coated PCS exhibits an excellent indoor water evaporation rate of 1.53 kg m-2h−1 and efficiency as high as 84.2 % under 1 sun irradiation, and the evaporator shows good stability in 10 cycles of solar evaporation experiments. Moreover, the PCS maintains a high evaporation rate of ∼ 2.4 kg m-2h−1 and good salt resistance in a long-term real seawater experiment for seven consecutive days. When this evaporation experiment was operated outdoors, high water purification capacity could be achieved. In total, PDA coated porous HNTs ceramic scaffolds show promising potential for application in the fields of solar thermal conversion and seawater desalination.

Stabilizing zinc powder anodes via bifunctional MXene towards flexible zinc-ion batteries

Flexible zinc (Zn) batteries have gained considerable attention as wearable energy storage devices because of their inherent safety and high theoretical capacity. However, conventional Zn anodes suffer from dendrite growth, high rigidity, and poor cycling stability issues, hindering their practical application in flexible zinc-ion batteries. Herein, a dendrite-free and flexible Zn anode is designed using direct ink writing (DIW) printed MXene as a flexible and highly conductive current collector and MXene-wrapped Zn powder (ZnP) as the active material by carefully optimising the rheological properties of MXene-based dispersion. As a result, the synergistic effects of the MXene-based current collector and the MXene protective layer promoted dendrite-free Zn deposition and prevented side reactions, achieving an outstanding cycling performance that exceeded 130 h at a high depth of discharge of 30%. When paired with a Vanadium pentoxide (V2O5)-based cathode, the flexible full cell demonstrated stable electrochemical performance under mechanical deformation and can power electronic devices, presenting a promising pathway for the development of flexible zinc-ion batteries.

Architected Design and Fabrication of Soft Mechanical Metamaterials

This study proposes a systematic design approach to 3D print soft mechanical metamaterials by tuning material flow behavior and using optimal toolpaths and print parameters. Planar printing tool paths, utilized in layer‐by‐layer printing such as fused deposition modeling (FDM) and prevalently used in most slicing algorithms, severely limit the realization of complex topologies required in metamaterials. Utilizing parametric design principles, the proposed approach employs discrete and continuous 3D freeform tool paths for supported and unsupported direct ink writing (DIW) of elastomeric structures. The resulting textured, soft topologies significantly enhance the performance of various mechanisms in soft robotics and impact energy‐absorbing wearable devices. Various bioinspired structures such as cilia, webs, leaf‐like structures, and lattices are explored using extrusion‐based silicone 3D printing, achieving features with high aspect ratios (L/D ≤ 12) without support. These complex structures are challenging to 3D print using conventional planar toolpaths. To demonstrate the enhanced functionalities enabled by these new topologies, cilia arrays added to suction cups increased the pull‐off forces by 18%. Additionally, 3D‐printed elastomeric lattice slabs used as energy‐absorbing structures reduced the maximum impact peak forces by 85%. Further functionalities, including magnetic, thermochromic, and signal transmission properties, are also showcased using functional soft mechanical metamaterials.

Phase change-mediated core-sheath 3D printing of hollow microlattice pseudocapacitive aerogel electrode with favorable electrochemical properties

Channel-interconnected regulation within 3D-printed pseudocapacitive electrode architecture to generate high active material loading/utilization and fast ion transport is pivotal but challenging for implementing high-performance pseudocapacitance system. Herein, we demonstrated an innovative phase change-mediated core-sheath direct ink writing (DIW) 3D printing strategy for controllably constructing pseudocapacitive hollow-microlattice graphene/NiCo2O4 aerogel (HGNA) electrode, with regular hollow channels in printed filaments and abundant well-interconnected hierarchical pores built by jointing tortuous pseudocapacitive graphene nanosheets. The unique architectural features facilitated highly efficient diffusion and infiltration of substance throughout the entire thick filaments from both “interior-exterior” and “exterior-interior” directions, thereby enabling high-level yet effective loading of active materials as well as unimpeded ion transport across the printed bulk-structured electrode. Kinetics analysis revealed that the capacitance of pseudocapacitive HGNA electrode was primarily contributed from fast kinetic process. An asymmetric device assembled with DIW-printed HGNA electrode boasted a high energy storage performance with capacitance of 3.43 F cm−2 and energy density of 1.01 mWh cm−2, while featuring remarkable cycling stability (87% after 8000 cycles) and superior capacity even at large electrode thickness. This work opens a promising route for processing rational pseudocapacitive electrode architectures toward high-capacity, fast-kinetics devices.

Engineering the Atomic Interface of Refractory‐Metal‐Reinforced Copper Matrix Using Direct Ink 3D Printing

Herein, 3D printing involving metallic materials with substantially distinct melting temperatures and their immiscibility presents a formidable challenge. Nevertheless, it may be possible to overcome this challenge using the direct ink writing (DIW) method within such immiscible systems. In this article, a successful fabrication of Cu‐based composites utilizing the additive manufacturing process that is DIW technique, followed by a post‐sintering process, is presented. The secondary addition to the Cu–matrix includes tantalum (Ta), tungsten (W), and niobium (Nb). The rheological properties of the composite inks are also analyzed for the DIW technique. The underlying reasons behind the increased mechanical, wear, and thermal properties are assessed through experimental and molecular dynamics simulations. Microstructural analysis is conducted using optical and scanning electron microscopes. Mechanical, electrical, thermal, and wear properties are evaluated at ambient temperature, and comparisons are established with DIW‐processed pure Cu. Elemental mapping through energy‐dispersive spectroscopy and high‐resolution transmission electron microscopy confirm the distribution of W, Ta, and Nb particles within the composite. The 3D printing of immiscible alloy components opens new avenues for exploring novel material properties, mixtures, and composite materials, thus fostering the development of innovative materials.