Dylan Hoskins from HADDY on the Future of Large-Scale 3D Printing

Dylan’s interest in 3D printing began during his time as a graduate research assistant at the University of Tennessee, where he worked alongside Oak Ridge National Laboratory. His early focus was on understanding how polymers behave as they pass through extruder screws. This foundational experience eventually led him to Local Motors, where he worked on 3D printing electric vehicle chassis, and later to his current role at HADDY.

HADDY began with a goal to change the furniture industry by using large-scale 3D printing. The company saw the environmental challenges in traditional furniture production, particularly when it came to recycling foam-based materials. By combining additive and subtractive manufacturing, HADDY developed a system where thermoplastic furniture can be returned, ground into pellets, and used to create new products. This closed-loop process helps reduce waste and promote sustainability.

HADDY has recently expanded its efforts, looking beyond furniture to produce non-structural architectural and aesthetic elements for different applications.

One of the key advantages of large-scale 3D printing is the ability to create complex, single-piece structures without the need for assembly. Unlike small-scale 3D printing, which often involves gluing and fastening parts together, HADDY’s approach enables faster production and greater structural integrity.

“We’re not trying to compete with injection molding, but we’re focusing on the middle ground where you need more than a few parts but fewer than a hundred thousand. Large-scale printing allows us to offer innovative, sustainable solutions at a faster pace.”

While large-scale 3D printing offers numerous advantages, it also presents unique challenges. Designing for large-scale manufacturing requires a different approach compared to smaller prints. Factors like smooth transitions, managing start-stop points, and understanding how materials behave at a larger scale all need careful attention.

Dylan is optimistic about the future of large-scale additive manufacturing, with a focus on making the process more automated and efficient. He believes that improvements in AI-driven monitoring and real-time adjustments will help make 3D printing more reliable and accessible.

Sustainability remains a core focus, and Dylan sees a continued push toward finding new ways to reduce waste, improve recyclability, and develop eco-friendly materials as additive manufacturing continues to evolve.

A key takeaway from Dylan’s discussion was the vital role of communication and collaboration in additive manufacturing. He emphasized that the industry flourishes through the open exchange of ideas and that building strong partnerships—both within organizations and with software providers—is essential for driving innovation. Dylan highlighted how Aibuild as a tool is revolutionizing the field by optimizing the design and printing workflow. The advancements are crucial in refining large-scale 3D printing, enabling manufacturers like HADDY to achieve the precision and efficiency required for high-quality production.

With companies like HADDY leading the charge in sustainable and large-scale 3D printing, the industry is poised for significant advancements. Whether it’s transforming furniture production or expanding into the built environment, additive manufacturing is proving to be a powerful tool for innovation. As technology evolves, the possibilities for large-scale 3D printing are limitless.