Multi-Material 3D Printing: Applications & Tips

Since the launch of our UltiMaker 3 in 2016, one of the first desktop printers to offer reliable dual extrusion capabilities, we have been at the forefront of multi-material 3D printing.

Now with the launch of our UltiMaker S8 we continue to build on this legacy and work towards offering engineers and manufacturers a robust platform for producing complex, high-performance parts.

In this article, we’ll explore the key benefits of multi-material 3D printing, some of the practical applications, and the best practices for achieving optimal results.

What is multi-material 3D printing?

Multi-material 3D printing is the process of combining two or more distinct materials within a single print to achieve parts with varied functional, mechanical or aesthetic properties.

With the advent of different solutions that enable 3D printers to use more than one filament for any given print, the use of “multi-material printing” has gotten somewhat conflated with “multi-color printing” so it’s important to distinguish between the two:

Multi-material printing: Involves the use of two or more distinct materials within a single print job. This allows for the creation of parts that have multiple functional or mechanical properties, such as flexibility and rigidity in one cohesive design.

Multi-color printing: Involves using a single material type, like PLA, with different colors to enhance visual appearance, without altering the part’s functional characteristics.

While both approaches offer creative flexibility, true multi-material printing enables far greater design and engineering possibilities.

Types of multi-material printing solutions

When looking into multi-material printing, it’s important to take into consideration the different pros and cons of each solution to make an informed decision. The most common options currently available are:

Dual-extruder systems

The most reliable professional solution that features two independent print cores.

Pros: Proven, easy to use, fast print times with minimal complexity, and in the case of UltiMaker 3D printers, fully supported by preset slicing profiles optimized for printing.

Cons: Limited to two materials per print.

Single nozzle multi-material feeders

Where a single nozzle printer uses a separate filament changing system that switches between multiple filaments feeding them in turns into the hotend.

Pros: More affordable, allows multiple materials or colors with fewer hardware changes (though most solutions of this type require an add-on material changing solution).

Cons: Significant purge waste, longer print times (due to the time it takes to switch between the filaments), limited to materials with similar printing temperatures and adhesion properties.

Tool-changing systems:

Where the printer swaps entire tool heads with different nozzles and materials mid-print.

Pros: High flexibility with independent material setups and nozzle sizes.

Cons: Slow multi-material print times, complex setup and maintenance, more suited for research rather than professional industrial workflows.

Benefits of multi-material 3D printing

Multi-material 3D printing provides significant advantages for engineers, designers and manufacturers enhancing design flexibility, functional integration and manufacturing efficiency.

We’ve outlined some of the key benefits below along with a few example applications.

Fabrication of complex geometries

With multi-material 3D printing, users can integrate soluble support materials like PVA which enable the production of intricate structures with overhangs and internal cavities that would otherwise be impossible to manufacture as a single part.

For example, UltiMaker’s dual-extrusion technology facilitates the creation of complex geometry designs by allowing the use of water-soluble supports which can be easily removed post-printing.

This can be an especially useful feature when integrated into existing manufacturing processes like custom mold creation, which is normally are time-consuming and expensive process.

We’ve just recently covered how 3D printing can be used to create significantly cheaper castings of engine parts, where parts were printed with water-soluble supports that allowed for structures with complicated cavities to be manufactured while maintaining a high-quality surface.

Integration of diverse material properties

Multi-material printing allows for the combination of materials with different mechanical characteristics within a single component. For example, parts that require both rigidity and flexibility can be printed by combining stiff materials with flexible ones.

Another example of an application, used by Heineken Sevilla, is this can pusher part which combines PLA (used for the inside of the part) with Nylon (used as a wear-resistant material for the outer layer).

Aside from the mechanical benefits of combining the two different materials, the use of different colors means that the internal red PLA acts as a wear indicator becoming more visible as the outer Nylo layer wears down.

Design and product optimization

From rapid prototyping to on-demand production, 3D printing allows manufacturers to save costs, decrease lead times, maintain production uptimes and minimize waste. Each of these advantages are further compounded by multi-material printing capabilities as printed parts can be optimized further in a myriad of ways:

Components like infeed wheels can have the bulk of their structure printed from a stiff high resistant material and have their outer wall printed with a low friction material to increase the component’s longevity in a production line.

In a nutshell, multi-material 3D printing empowers engineers to design and manufacture assembly-free complex parts that integrate multiple functional properties within a single build. By enabling the combination of rigid, flexible, and soluble materials with different mechanical properties within a single print, multi-material 3D printing effectively streamlines product development and improves on manufacturing efficiency.

Ensuring success in multi-material 3D printing

Multi-material 3D printing can deliver exceptional results, but achieving consistency and reliability requires more than just the right hardware. Engineers must carefully consider material behavior, printer capabilities and workflow management.

UltiMaker’s ecosystem, including Cura, Digital Factory, and the advanced features of the S8, is designed to remove many of these barriers.

General best practices for multi-material success

• Store materials properly to keep hygroscopic materials (PVA, nylon, TPU) in sealed dry boxes.
• Perform regular nozzle maintenance to avoid contamination between materials.
• Calibrate nozzle offsets and run bed leveling frequently, especially when switching between material combinations.
• Optimize purge tower settings to balance material waste and quality transitions between materials.
• Design with intent to create parts with clear material boundaries and consider using interlocking geometries where mechanical strength is required.
• Start with small calibration tests before committing to production-scale prints.
• Slow down print speeds for critical areas or transitions between materials to ensure smooth bonding and aesthetic finish.

Overcoming material compatibility

One of the most common challenges in multi-material printing is ensuring proper bonding between dissimilar materials. Normally, users would need to consult a material compatibility chart like this one in order to tell if the materials would work together as many of them need to be printed at different temperatures while others are simply chemically incompatible.

UltiMaker Cura’s Material Interlocking feature (available in Cura 5.3 and later versions) overcomes this by generating a geometric overlap structure at the material boundaries, mechanically locking materials together. This allows engineers to confidently combine materials that traditionally wouldn’t adhere, making any material fair game.

Streamline production with UltiMaker Digital Factory integration

Managing multi-material projects often involves complex preparation, monitoring, and iteration. The UltiMaker Digital Factory simplifies this by providing:

• Cloud-based model preparation and slicing
• Remote printer management
• Real-time monitoring and reporting
• Team collaboration tools and usage analytics

This integrated workflow allows engineering teams to manage multiple printers, jobs, and material setups from a single platform, reducing downtime and streamlining communication across departments.

Speed, reliability, and consistency with the UltiMaker S8

The UltiMaker S8 is engineered to deliver fast, consistent, and reliable dual-material 3D printing for professional environments. With a focus on high productivity and accuracy, it enables engineers to produce complex, multi-material parts with confidence.

Key features supporting multi-material performance:

• Dual extrusion with interchangeable high flow print cores (AA, BB, CC) makes switching between different build and support materials seamless and efficient.
• The new UltiMaker Cheetah motion planner enables movement speeds of up to 500 mm/s and acceleration up to 50,000 mm/s², maintaining print quality while significantly reducing build times.
• A re-engineered material feeder with hardened steel gears ensures reliable filament handling, reducing slip and maintaining consistent extrusion, even with flexible and abrasive materials.
• Active build plate leveling and dual filament run-out sensors safeguard long, complex builds, ensuring consistency and reducing the risk of failed prints.
• NFC material recognition automatically detects and applies the correct material profiles, streamlining setup and reducing operator error.
• Full integration with UltiMaker Digital Factory provides cloud-based management for print job preparation, slicing, queuing, monitoring, and collaboration, ideal for multi-user, multi-printer environments.

Advancing design and manufacturing efficiency

Multi-material 3D printing is no longer a niche capability, it is a practical tool for engineers and manufacturers looking to accelerate product development, optimize part functionality, and reduce production complexity.

By combining distinct material properties within a single build, professionals can achieve design freedom and performance beyond the reach of traditional manufacturing methods.

See the UltiMaker S8 and its advanced multi-material capabilities can elevate your engineering and production workflows.