Printing the Future: Building Innovation Layer by Layer
What if the solution to complex, urgent problems could be built layer by layer? Imagine a new-born struggling for breath in a hospital, where a simple but vital medical device, a suction tube, has run out of stock. The last craftsman who made these glass tubes retired, and the supply chain for replacements is broken. How do you bridge the gap when lives are at stake?
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Now picture a local business that needs a prototype to showcase its innovative designs to a global client. Traditional manufacturing methods are costly, slow, and wasteful. How can they keep up in a fast-paced, resource-conscious world?
A technology that produces fast and with little waste
These challenges, whether saving lives or driving business innovation, demand creative, cutting-edge solutions. That’s where 3D printing comes in: a ground-breaking technology that constructs objects with high precision, using only the material required. By minimising waste and accelerating production, it has become a game-changer, revolutionising industries from healthcare to construction with its versatility and efficiency. Supported by the Interreg North Sea, the SUSTAIN-3D project explores the ability of 3D printing to solve urgent issues. From saving the lives of premature babies to helping businesses adopt sustainable models, the project is turning the promise of this technology into real-world impact, one layer at a time.
Poul Erik Mortensen leads the project. At 73, he brings a wealth of experience and energy to his work. With over 30 years at one of the world’s largest pump companies, he has built networks across Africa, Brazil, Japan, and beyond. With SUSTAIN-3D, he is now focusing on 3D printing as a potential tool for change.
During the COVID-19 pandemic, Poul showcased the life-saving potential of 3D printing when a hospital faced a critical shortage of suction tubes for newborns. The original supplier had retired, leaving no immediate replacement. ‘We took one of the remaining glass tubes, scanned it, and printed a prototype,’ Poul recalls. Initially, they used PLA, a biodegradable plastic filament, to perfect the dimensions. Then, they transitioned to resin, producing transparent tubes that met the hospital’s requirements perfectly. In the end, hundreds of these vital tubes were manufactured, proving that 3D printing isn’t just a problem-solving tool—it can save lives.
Mapping the state of 3D in the North Sea region
Coming back to SUSTAIN-3D, the project aims to bring together partners from Denmark, Belgium, the Netherlands, and France. Each partner adds complementary skills and expertise to the others. They map the state of 3D printing in the region. By examining skills, infrastructure, and services, the project lays the groundwork for targeted interventions that can help bridge gaps and accelerate adoption across the region. While this serves as a blueprint for targeted interventions for Poul, the benefits go beyond: “It’s not just about mapping, it’s about teaching each other, learning from each other. That’s how we grow together.”
For Poul, leading SUSTAIN-3D is the culmination of decades of experience building international networks and his passion for making a tangible difference. His commitment to 3D printing isn’t just about its technological potential, it’s about the positive, sustainable impact it can create for communities and businesses. This personal vision drives the project toward a clear goal: to demonstrate that 3D printing can impact society, empower industries, and help build a more sustainable future.
There is no education for 3D printing engineers
An example of this collaboration comes from Belgium, where project partners observed a unique use of robotics in 3D printing. “In their lab, they have a robot combined with a 3D printer that works like a welding machine, adding material layer by layer. We learned from that and are now testing similar methods with our own setups in Denmark”.
One of the most significant insights from this initiative has been the need to address the skills gap. “There’s no education for 3D printing engineers, not in Denmark, not in Belgium, not in France,” highlighting the opportunity for growth. “Meanwhile, in the U.S. and China, they already have programs dedicated to this field.” While Europe has some catching up to do, this challenge also represents a chance to build a strong foundation for the future. “This isn’t just a technology issue; it’s a skills issue. With the right people, we can move forward and unlock the full potential”.
The need to take 3D from the kitchen to the company
Looking to the future, Poul believes the solutions are already within reach. “The demand is there,” he says. “Young people are sitting at home, playing with 3D printers in their kitchens. They’re creating things that could be the start of real innovations. But we need to take them from the kitchen to the company. We need to scale up their potential.” For him, the vision goes beyond industry, it’s about creating a sustainable legacy. “3D printing isn’t just a tool for making things. It’s a tool for solving problems. Whether it’s using recycled materials to create filament or printing medical devices to save lives, it has the potential to change the world. But it has to be done right.” As example he adds, “There’s an enormous resource ready to be picked up, plastic in our oceans, waste all around us. We can turn that into something valuable. At the same time, we clean our environment. It’s a win-win.”
As SUSTAIN-3D nears its conclusion, Poul reflects on what’s next. “My dream is to keep the momentum going, to push for education, to make sure this technology is accessible and impactful. If we can dream it, we can do it,” he says with conviction. “And if we do it right, we’re not just building things, we’re building a better future.”
While this journey moves forward, it becomes a powerful example of how collaboration and innovation can reshape industries and communities. By unlocking the potential of 3D printing, the initiative is not only transforming the way we create but also tackling critical challenges like sustainability and access to technology. It’s about more than machines; it’s about people, ideas, and the impact we can achieve together. With cross-border partnerships and a focus on the future, this work shows how shared knowledge and bold thinking can lay the foundation for a more connected, innovative, and sustainable tomorrow.
