Extrusion Nozzle Research Articles

Modeling fiber alignment in 3D printed ultra-high-performance concrete based on stereology theory

This paper introduces a theoretical model for forecasting fiber orientation in 3D-printed ultra-high-performance concrete (3DP-UHPC). Initially, the dynamic evolution process of fiber alignment in 3DP-UHPC was characterized using X-ray computed tomography (X-CT) and image analysis. The results indicated that fiber alignment during extrusion process was primarily constrained by the rigid boundary of nozzle. Leveraging stereology theory, the regularity of fiber alignment affected by boundary effects was elucidated. Following layer deposition, the flattening effect resulting from the nozzle's extrusion force and gravity of upper layers influenced fiber alignment along printing direction. To quantify this impact, a flattening correction coefficient was introduced to modify fiber orientation coefficient in an ideal state. Finally, considering the overlapping effect of boundary and flattening on fiber orientation in 3DP-UHPC, a theoretical model was developed to predict fiber orientation. The model demonstrated robust adaptability, providing valuable insights into the design of 3DP-UHPC with improved fiber reinforcement efficiency.

Multiscale analysis of interlocking effects for polymer additive manufacturing on aluminum foam

AbstractHybrid structures are increasingly relevant for lightweight design and functional components. Various manufacturing techniques for creating hybrid components exist, often focusing on combining metal and polymer components. The present study examines a novel approach for manufacturing hybrid functional structures by directly printing thermoplastic onto aluminum profiles using closed‐cell aluminum foam, with the mechanical interlocking resulting in a structural bond. The filling of pores in the aluminum foam with the polymer affects the bond strength of this hybrid compound. Within a simulation‐based process design the additive manufacturing process parameters are investigated using a computational fluid dynamics (CFD) model with Fluid‐Structure Interaction for the pore‐filling process and a finite element (FE) model to evaluate the resulting bond strength. The material throughput, the nozzle distance, and the polymer temperature are the key process parameters taken into account. A parameterized, virtual foam model is used within this framework, where a linear movement of the extruder nozzle and the resulting polymer strand is investigated. This method includes the mesh conversion from the CFD results to the FE mesh for structural analysis by exporting the iso‐surface for the polymer geometry embedded in the pores of the aluminum foam structure. This approach made it possible to investigate the phenomena that occur in the process in more detail, particularly to quantify the influence of air inclusions. Thus, a decisive contribution to the hybridization of aluminum foams has been made, which opens up further potential for research and application in the long term.

Influence of additive manufacturing parameters by FFF on PLA tensile strength

When na object manufactured by 3D printing goes from prototype to a functional component, it is crucial to understand the mechanical properties of the material used. This knowledge determines the resistance limits of the object. Therefore, the objective of this research was to comparatively analyze the results obtained in tensile tests of specimens constructed with polylactic acid (PLA), printed in 3D, keeping the density constant and varying two construction parameters: the layer thickness and the geometry of the internal filling. The test specimens were made on a BFB Touch – Dual head-smoke 3D printer, in accordance with ASTM D638-14. Tensile tests were carried out using an EMIC model DL10000 testing machine, and the results were statistically analyzed for comparison. The results indicated that the maximum stress and fracture resistance increased with increasing thickness of the filament deposited by the extruder nozzle. Although PLA is often described in the literature as a brittle polymer, it has exhibited ductility characteristics when 3D printed, due to the alignment of fibers during the manufacturing process.

Thermal and energy efficiency in 3D-printed buildings: Review of geometric design, materials and printing processes

Applying 3D printing in construction is a promising, sustainable alternative to conventional methods. However, the thermal and energy performance of 3D-printed buildings remains underexplored, particularly regarding the interactions between geometric design, material selection, and printing parameters. This review addresses this gap by critically examining how the main steps of the printing process impact the thermal efficiency of 3D-printed buildings. Key findings indicate that material development needs to focus on mixes that balance thermal properties,printability,and structural integrity. The review demonstrates how optimising wall cross-sections and cavity shapes can reduce thermal conductivity and enhance energy efficiency. Innovative geometric designs, such as cellular and honeycomb structures, have shown improvements in thermal insulation. Optimising printing parameters, such as extrusion rate and nozzle travel speed, is crucial to minimising thermal bridges and reducing material anisotropy. Advanced numerical models, validated by experimental data and incorporating factors like inhomogeneous porosity, anisotropy, and surface roughness, are essential for accurately predicting the thermal behaviour of 3D-printed structures. The review underscores the need for large-scale, long-term performance studies of 3D-printed buildings under diverse climatic conditions. Additionally, developing standardised fabrication protocols and testing methods is essential for ensuring consistent quality and broader adoption. Addressing these research gaps is crucial to fully realising the potential of 3D printing in sustainable construction and accelerating the adoption of additive manufacturing in the construction sector.

Influence of extruder geometry and bio-ink type in extrusion-based bioprinting via an in silico design tool

Planning a smooth-running and effective extrusion-based bioprinting process is a challenging endeavor due to the intricate interplay among process variables (e.g., printing pressure, nozzle diameter, extrusion velocity, and mass flow rate). A priori predicting how process variables relate each other is complex due to both the non-Newtonian response of bio-inks and the extruder geometries. In addition, ensuring high cell viability is of paramount importance, as bioprinting procedures expose cells to stresses that can potentially induce mechanobiological damage. Currently, in laboratory settings, bioprinting planning is often conducted through expensive and time-consuming trial-and-error procedures. In this context, an in silico strategy has been recently proposed by the authors for a clear and streamlined pathway towards bioprinting process planning (Chirianni et al. in Comput Methods Appl Mech Eng 419:116685, 2024. https://doi.org/10.1016/j.cma.2023.116685). The aim of this work is to investigate on the influence of bio-ink polymer type and of cartridge-nozzle connection shape on the setting of key process variables by adopting such in silico strategy. In detail, combinations of two different bio-inks and three different extruder geometries are considered. Nomograms are built as graphical fast design tools, thus informing how the printing pressure, the mass flow rate and the cell viability vary with extrusion velocity and nozzle diameter.

Feasibility of continuous switching 3D printing on surimi

Continuous switching 3D printing that allows multiple materials printed in a single nozzle was introduced to verify its applicability to the food system, which aims to improve the switching ability and manufacturing precision of multi-material 3D printed food. By integrating a self-developed 3D printing platform with logical adjustments of extrusion pressure and 3D motion, the feasible continuous switching of surimi was achieved. Moreover, employing a dual-channel continuous switching extrusion nozzle, the study elucidated the influence of surimi rheological properties on the interface behavior between pastes during extrusion. Through the analysis of fluid dynamics behavior of channel flow and utilization of simulation technology, a channel extension solution was formulated. Extending the length of the non-extrusion channel to 15 mm effectively prevented intrusion over 4 mm at an extrusion speed of 40 mm/s. This study managed to repetitively switch between two kinds of surimi pastes within a 2 mm unit length. Meanwhile, three types of 3D printing modes were established based on the control of Gcode, and the corresponding model offset correction enabled precise deposition of 2 mm × 1 mm units. The research also succeeded in 3D printing complex structures, such as meat-fat structure of beef based on surimi.

Competition between bead boundary fusion and crystallization kinetics in material extrusion-based additive manufacturing

Assembling polymer beads into well-defined 3D geometries through a layer by layer deposition process, such as material extrusion additive manufacturing, remains challenging due to the complex interplay between the several kinetics involved (flow, inter-beads diffusion/fusion, cooling, solidification, etc). Here, we explore the influence of physical parameters like bead cross section geometry, partial bead fusion (also called bead coalescence or bead welding) and crystallization kinetics on the 3D printing of isotactic polypropylene as a model semi-crystalline polymer. New methods for the characterization of printed stacks cross sections, interlayer cohesion and viscoelastic coalescence are introduced. Our results demonstrate how printing conditions, through input parameters like layer height and nozzle temperature, can greatly affect interlayer cohesion in relation to polymer interdiffusion at the interface. We show that the relevant timescale for fusion is mainly driven by the polymer’s rheology, and that fusion is many-fold faster under Hertzian compression, i.e. due to the effect of contact pressure. Quantitative description of the influence of the extrusion nozzle and build platform temperatures on the crystallization time of printed beads highlights how the processability window is defined by the competition between fusion and crystallization. Our approach therefore provides a framework for the optimization of process parameters based on the physical processes involved during the production run of semi-crystalline polymers.

Impact of strand deposition and infill strategies on the properties of monolithic copper via material extrusion additive manufacturing

The present research presents a comprehensive study on the process optimisation and characterisation of fully dense and pure Cu parts manufactured by Material Extrusion Additive Manufacturing (MEX). This technology is an emerging approach to additively manufacture high-performance metal components due to its multi-step nature that allows to shape and subsequently sinter complex design parts. A commercially available filament with 60 vol% (93 wt%) copper particles and polymeric binders was used and characterised in this study. Two approaches were combined for the first time to maximise the final density of the copper parts; a statistical approach (using ANOVA) and an optimisation approach based on the strand cross-section. Based on the former, the flow rate multiplier during printing has a significant effect on the density of the as-printed parts. The latter aimed at studying the effect of the ratio between extrusion width, layer height, and nozzle diameter on the deposited strand morphology. An extrusion width equal to and a layer height lower than the nozzle diameter contribute to precise strand dimensions, leading to improved control of the final green density. After solvent and thermal debinding followed by pressureless and supportless sintering in pure H2 at 1050 °C, the copper parts resulted in a relative density > 95 % and an electrical conductivity of ∼93 %IACS as an indication of the purity of the starting material and the quality of the whole process chain. Tensile testing of as-sintered dog-bone samples, built with 0°, 90° and ±45° infill patterns and a single wall contour, revealed the best results for the ±45° strategy with an ultimate tensile strength of 164 MPa and an elongation at fracture of 24 %. Finally, a copper coil for electromagnetic applications was manufactured, for the first time, via filament-based MEX and tested. It reported an electrical conductivity competitive to that reported in the literature (∼70 %IACS). This result was discussed in relation to a simple monolithic Cu geometry to provide insight into the complexity and concomitant scientific relevance of applying MEX to functional components.

Effects of high gravity on properties of parts fabricated using material extrusion system by additive manufacturing

Additive manufacturing (AM) has gained significant attention in recent years owing to its ability to fabricate intricate shapes and structures that are often challenging or unattainable using conventional manufacturing techniques. This high-quality development trend entails higher requirements for the structural design of 3D printers. In this study, polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) filaments were fed through a heated extrusion nozzle, which melted the material and deposited it onto a build platform. This study's objectives are high-gravitational material extrusion (HG-MEX) systems development, analyzing the high gravity influences on the flow behavior of materials during extrusion, and understanding the effects of gravitational on material flow and overall extrusion performance. HG-MEX systems have great potential for addressing various challenges in additive manufacturing, such as precise manufacturing. The highlight of the progress is that we developed an HG-MEX system and applied surface science to material extrusion in different gravity. We established a system and obtained results on different gravity, we analyzed the analogy between different gravity phenomena. We analyzed the interplay between the behavior of the fabricated parts and gravity. We analyzed high gravity effects on extrusion processes. The results confirmed the characteristics and feasibility of the developed system. The results suggest that a material extrusion line operating under 15 G conditions resulted in better printing quality compared to one operating under 1 G conditions. This observation implies that high gravity had a positive effect on the extrusion process, leading to improved material extrusion performance.

Additive manufacturing advancement through large-scale screw-extrusion 3D printing for precision parawood powder/PLA furniture production

In this paper, a large-scale screw-extrusion 3D printer specifically tailored for additive manufacturing applications is introduced, primarily focusing on crafting parawood powder/polylactic acid (PLA) furniture. Boasting a large build volume (700 × 700 × 700 mm3), the printer incorporates a meticulously designed screw extruder to ensure the precise feeding of composite material pellets. The investigation delves into the nuanced relationship between variations in the extruder nozzle orifice diameter and the resulting impact on the extrusion rate, directly correlating these variations with the motor speed. Additionally, the influence of the parawood powder/PLA ratio is explored through comprehensive mechanical property testing of the printed specimens. Optimal outcomes were attained with a 15 %w/w parawood powder composition, yielding an impressive ultimate strength of 54 MPa under specific printing conditions. The efficacy of the large-scale screw-extrusion 3D printer was robustly validated through the successful production of a parawood powder/PLA stacking chair, meeting the criteria stipulated in the Thai industrial standard. Furthermore, an identified parawood powder/PLA component, characterized by a rectangular cylinder with a cross-sectional area of 19.4 × 24.0 mm2, holds promising potential for versatile applications in furniture assembly. This innovative extrusion 3D printing approach, combined with meticulously optimized parameters, has unequivocal potential for manufacturing a diverse array of parawood powder/PLA furniture, elevating the value of parawood byproducts and contributing to waste reduction during processing.

Equipment design and parameters recommendation of rubber modified 3D printed asphalt in pavement maintenance

As an advanced technology for pavement crack maintenance with high automation level, high precision and high efficiency, 3D asphalt printing technology can effectively improve worker safety and ensure the stability of maintenance quality. In order to optimize the printing parameters of rubber modified 3D printed asphalt (R-3DPA), a three-axis asphalt 3D printer was developed in this study through the design and selection of each component, and it was used for the 3D printing of R-3DPA strips, layers, and structures. Based on the comparison of continuity, uniformity, and width of R-3DPA strips, the recommended extrusion nozzle diameter, printing temperature, and printing speed parameter combinations were superiorly selected. According to the analysis of filling degree, width error and thickness of R-3DPA layers, the optimal printing strip width was recommended. Through the evaluation of integrity, surface characteristics and accuracy of R-3DPA structures, the suitable printing layer thickness was determined. The test results showed that the three-axis asphalt 3D printer can be used to measure the parameters of R-3DPA, and the printing accuracy and scale meet the requirements. The recommended parameters for R-3DPA are an extrusion nozzle diameter of 2 mm, a printing temperature of 180 °C, a printing speed of 20 mm/s, a printing strip width of 2.25 mm and a printing layer thickness of 0.4 mm, resulting in structures with good integrity and precision.

Biotribological properties of 3D printed high-oriented short carbon fiber reinforced polymer composites for artificial joints

Short carbon fiber (SCF) reinforced polymer composites are expected to possess outstanding biotribological and mechanical properties in certain direction, while the non-oriented SCF weakens its reinforcing effect in the matrix. In this work, high-oriented SCF was achieved during nozzle extrusion, and then SCF reinforced polyether-ether-ketone (PEEK) composites were fabricated by fused deposition modeling (FDM). The concrete orientation process of SCF was theoretically simulated, and significant shear stress difference was generated at both ends of SCF. As a result, the SCF was distributed in the matrix in a hierarchical structure, containing surface layer I, II and core layer. Moreover, the SCF was oriented highly along the printing direction and demonstrated a more competitive orientation distribution compared to other studies. The SCF/PEEK composites showed a considerable improvement in wear resistance by 44 % due to self-lubricating and load-bearing capability of SCF. Besides, it demonstrated enhancements in Brinell hardness, compressive and impact strength by 48.52 %, 16.42 % and 53.64 %, respectively. In addition, SCF/PEEK composites also showed good cytocompatibility. The findings gained herein are useful for developing the high-oriented SCF reinforced polymer composites with superior biotribological and mechanical properties for artificial joints.

3D-printed scaffolds for tissue engineering applications using thermosensitive hydrogels based on biopolymer blends

Three-dimensional (3D) printing is an emerging technology for the construction of complex 3D constructs used for tissue engineering applications. In this study, we are proposing the preparation of 3D printing hydrogel inks consisting of the synthetic polymers poly(caprolactone) and poly(lactic acid), the biopolymer chitosan, and naturally derived gelatin. In addition, pluronic F-127 was used to improve the miscibility between the hydrophobic and hydrophilic components due to its amphiphilic character, as well as for its good 3D printability. The printability of the hydrogel inks was optimized by varying the composition, the extrusion nozzle, and the temperature, while the integrity of the 3D scaffolds was secured via sol–gel transition. The produced hydrogels with PCL-pluronic-chitosan-gelatin/15-20-4-2 wt% (PC3.75-Pl5-CG) and PLA-pluronic-chitosan-gelatin/10-20-4-2 wt% (PL2.5-Pl5-CG) presented the best printability, producing smooth and uniform porous scaffolds. The prepared hydrogels were formed via the interactions between the polymers through hydrogen bonding. Additionally, the produced hydrogels exhibited temperature-dependent swelling behavior, and the scaffolds with PCL presented lower swelling capacity than the scaffolds with PLA. The produced scaffolds presented slower hydrolyzation rate in simulated body fluid (SBF) at 25 °C compared to 37 °C. Biological studies proved that the 3D-printed porous scaffolds were non-cytotoxic and promoted human adipose-derived mesenchymal stem cell adhesion.Graphical abstract

3D concrete printing using computational fluid dynamics: Modeling of material extrusion with slip boundaries

This paper investigates the role of slip boundary conditions in computational fluid dynamics modeling of material extrusion and layer deposition during 3D concrete printing. The mortar flow governed by the Navier-Stokes equations was simulated for two different slip boundary conditions at the extrusion nozzle wall: no-slip and free-slip. The simulations were conducted with two constitutive models: a generalized Newtonian fluid model and an elasto-viscoplastic fluid model. The cross-sectional shapes of up to three printed layers were compared to the experimental results from literature for different geometrical- and speed-ratios. The results reveal that employing free-slip boundary conditions at the extrusion nozzle wall improves layer-mimicking quality for both constitutive models, indicating the presence and importance of a lubricating layer of fine particles at the concrete-solid wall interface. This enhanced performance is primarily due to the observed decrease in extrusion pressure that minimizes layer height- and width-deviations compared to the experimental prints. Furthermore, the free-slip boundary conditions play an important role in predicting the multilayer prints, its deformation and groove shapes.

Fabrication of a Controlled-Release Core-Shell Floating Tablet of Ketamine Hydrochloride Using a 3D Printing Technique for Management of Refractory Depressions and Chronic Pain.

In this study, a novel floating, controlled-release and core-shell oral tablet of ketamine hydrochloride (HCl) was produced using a dual extrusion by 3D printing method. A mixture of Soluplus® and Eudragit® RS-PO was extruded by a hot-melt extrusion (HME) nozzle at 150-160 °C to fabricate the tablet shell, while a second nozzle known as a pressure-assisted syringe (PAS) extruded the etamine HCl in carboxymethyl cellulose gel at room temperature (25 °C) inside the shell. The resulting tablets were optimized based on the United States pharmacopeia standards (USP) for solid dosage forms. Moreover, the tablet was characterized using Fourier-transform infrared (FTIR) spectrum, scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and buoyancy techniques. The results showed a desired dissolution profile for a 100% infill optimized tablet with total drug release (100%) during 12 h. Weight variation and content uniformity of the tablets achieved the USP requirements. SEM micrographs showed a smooth surface with acceptable layer diameters. According to the FTIR analysis, no interference was detected among peaks. Based on DSC analysis, the crystallinity of ketamine HCl did not change during melt extrusion. In conclusion, the floating controlled-release 3D-printed tablet of ketamine HCl can be a promising candidate for management of refractory depressions and chronic pain. Additionally, the additive manufacturing method enables the production of patient-tailored dosage with tunable-release kinetics for personalized medicine in point-of care setting.

Modulation of starch structure, swallowability and digestibility of 3D-printed diabetic-friendly food for the elderly by dry heating

Elderly people often experience difficulty in swallowing and have impaired regulation of the nervous system. Furthermore, their blood glucose level can rise easily after eating. Therefore, functional foods that are easy to swallow and can maintain blood glucose at a lower level have been an important research topic in recent years. In this study, 3D printing was combined with dry heating to modify the starch in white quinoa and brown rice to develop whole grain foods with Osmanthus flavor that meet the dietary habits of the elderly. The samples were tested for printability, swallowing performance, and in vitro digestion. The results showed that after dry heating, all samples had shear-thinning properties and could pass through the extrusion nozzle of the printer smoothly. Both white quinoa and brown rice showed improved printability and self-support compared to the control. B45 (white quinoa, dry heating for 45 min) and C45 (brown rice, dry heating for 45 min) had significant elasticity and greater internal interaction strength during swallowing to resist disintegration of food particles during chewing. B45, C30, and C45, conformed to class 4 consistency and were characterized by easy swallowing of the diet. Further, dry heating resulted in greater resistance to enzymatic degradation of white quinoa and brown rice starch, with overall in vitro digestibility lower than the control.

Harnessing Path Optimization to Enhance the Strength of Three-Dimensional (3D) Printed Concrete

The path-dependent strength of three-dimensional printed concrete (3DPC) hinders further engineering application. Printing path optimization is a feasible solution to improve the strength of 3DPC. Here, the mix ratio of 3DPC was studied to print standard concrete specimens with different printing paths using our customized concrete 3D printer, which features fully sealed extrusion and ultrathin nozzles. These paths include crosswise, vertical, arched, and diagonal patterns. Their flexural and compressive strengths were tested. In order to verify the tested results and expose the mechanism of strength enhancement, digital image correlation (DIC) was used to capture the dynamic gradual fracture in the flexural tests. Also, the meso- and microstructures of the 3D-printed concrete specimens were pictured. The results reported here show that arched-path concrete has 30% more flexural strength than others because it makes better use of filament-wise strength. The findings here provide a pathway to improve the strength of 3D-printed concrete by path optimization, boosting 3DPC’s extensive application in civil engineering.

Exploring a Novel Material and Approach in 3D-Printed Wrist-Hand Orthoses

This article proposes the integration of two novel aspects into the production of 3D-printed customized wrist-hand orthoses. One aspect involves the material, particularly Colorfabb varioShore thermoplastic polyurethane (TPU) filament with an active foaming agent, which allows adjusting the 3D-printed orthoses’ mechanical properties via process parameters such as printing temperature. Consequently, within the same printing process, by using a single extrusion nozzle, orthoses with varying stiffness levels can be produced, aiming at both immobilization rigidity and skin-comfortable softness. This capability is harnessed by 3D-printing the orthosis in a flat shape via material extrusion-based additive manufacturing, which represents the other novel aspect. Subsequently, the orthosis conforms to the user’s upper limb shape after secure attachment, or by thermoforming in the case of a bi-material solution. A dedicated design web app, which relies on key patient hand measurement input, is also proposed, differing from the 3D scanning and modeling approach that requires engineering expertise and 3D scan data processing. The evaluation of varioShore TPU orthoses with diverse designs was conducted considering printing time, cost, maximum flexion angle, comfort, and perceived wrist stability as criteria. As some of the produced TPU orthoses lacked the necessary stiffness around the wrist or did not properly fit the palm shape, bi-material orthoses including polylactic acid (PLA) inserts of varying sizes were 3D-printed and assessed, showing an improved stiffness around the wrist and a better hand shape conformity. The findings demonstrated the potential of this innovative approach in creating bi-material upper limb orthoses, capitalizing on various characteristics such as varioShore properties, PLA thermoforming capabilities, and the design flexibility provided by additive manufacturing technology.

Effect of nozzle wear on mechanical properties of 3D printed carbon fiber-reinforced polymer parts by material extrusion

A widespread problem of manufacturing processes is represented by the occurrence of tool wear that can lead to both poor surface finish and poor mechanical properties in the workpiece. This issue affects also additive manufacturing technologies such as the material extrusion technique. In this process, the wear mechanisms of the extrusion nozzle can be severe, in particular when materials with a high abrasive capacity, such as carbon fiber-reinforced polymers, are 3D printed. Despite the significance of this problem, scientific literature lacks systematic evaluations of nozzle wear and its correlation with parts mechanical properties. In this framework, the present paper aims at investigating the effect of the nozzle wear evolution on the mechanical properties of additively manufactured parts in short carbon fiber-reinforced polyamide. To this purpose, 3D printing processes were performed. The time dependence of the nozzle wear was analyzed by interrupting the additive manufacturing process at fixed time intervals. To analyze the effect of nozzle wear on the mechanical performances of printed parts, tensile specimens were 3D printed and tested at room temperature. A reduction in mechanical performances of the printed samples and a worsening in the surface quality were observed with increasing the nozzle wear. Optical microscopy investigation and X-ray computed tomography were used to monitor the external and internal nozzle wear evolution. The surface roughness measurements were performed to evaluate the surface quality of the 3D printed parts. Furthermore, the scanning electron microscopy was used to observe the three-dimensional topography of the longitudinal sections of filament in Carbon PA, at different printing time values, and fractured surfaces of tensile samples. This study can help to better understand nozzle wear and to predict tool service life for industrial applications. In addition, it can prompt future studies focused on the reduction of tool wear.

Robotic Conformal Material Extrusion 3D Printing for Appending Structures on Unstructured Surfaces

Fabrication of structures in unstructured conditions is a promising area of bolstering the application spaces of additive manufacturing (AM). One emerging application is appending structures on existing ones that may have nonplanar surfaces in unconventional orientations. However, extrusion‐based AM techniques are limited to printing on structured, planar environments with a fixed single‐nozzle direction. Herein, the authors present a dexterous conformal material extrusion printing method using a six‐axis robotic arm capable of constructing complex parts onto highly unstructured surfaces with rough topographies. The manufacturing method employs a custom algorithm that generates layers consisting of 3D spatial coordinates of print path as well as the extrusion nozzle oriented in the normal direction of the substrate, thereby enabling conformal motion of the extrusion nozzle to the unstructured surface. The capabilities of the surface‐informed robotic conformal 3D printing method to fabricate structures on surfaces with a variety of topographies in unconventional orientations are demonstrated. Finally, via addition of deposited conductive paths, a high‐strength, functional reinforcement capable of in situ deformation monitoring is appended. This work has the potential for reconstructing, repairing, and reinforcing existing structures in human‐limited or inaccessible spaces. Integration of functional elements can also enable in situ sensing, monitoring, and self‐diagnosis.