Inside 3D Printing: Professor Neil Hopkinson on Innovation, Scale, and the Future

Professor Neil Hopkinson has been a leading figure in additive manufacturing (AM) since 1993, holding research appointments at the University of Sheffield, Loughborough University, De Montfort University, 3D Systems, and the University of Nottingham. In January 2016 he became Director of 3D Printing at Xaar, the global pioneer of industrial inkjet technology, to expand their 3D‑printing portfolio. Hopkinson is the inventor of High‑Speed Sintering (HSS), a highly efficient AM process that combines inkjet printheads with infrared heaters to build parts from polymer powders.

Interview with Professor Neil Hopkinson

AMFG: How did your academic interest in additive manufacturing originally develop?

Neil: I studied Manufacturing Engineering and Operations Management at the University of Nottingham. In my final year (1992/93) I first heard about “Rapid Prototyping” and was immediately captivated by its transformative potential.

AMFG: What have been the most significant developments in AM since you published your first book on the subject?

Neil: Two milestones stand out:

1. The commercial adoption of the “print‑and‑sinter” approach in polymer powder‑bed systems.
2. Continuous DLP‑enabled photo‑curing.

Both have proven to be game‑changing for the industry.

AMFG: What do you see as the principal advantages of inkjet‑based AM compared to other methods?

Neil: Scalability is the key. As a manufacturing engineer, I aim to make AM a standard volume‑production process. Industrial‑grade inkjet technology offers the most realistic path to that goal, and it supports a broad range of materials—including thermoplastics, thermosets, and metals.

AMFG: What are the primary challenges for companies exploring AM as a production tool for the first time?

Neil: Choosing the right technology is the biggest hurdle. The market is saturated with processes, and newcomers often need expert guidance to identify the best fit for their needs.

AMFG: At the other end of the spectrum, what key opportunities does AM offer for the industrial sector that you envisage companies exploring further?

Neil: AM is becoming a credible production method, including for volume runs. This opens profound opportunities by eliminating tooling:

• Design freedom for lightweight parts (aerospace, automotive)
• Enhanced performance parts (sports, leisure)
• Personalised products (healthcare)
• Rapid response to market trends (fast‑moving consumer goods, toys)

AMFG: How do you see AM evolving in the near future? What are the key issues that need to be addressed for 3D printing technology to reach the next stage?

Neil: We will see a rapid uptick in volume production use. The technology is mature; the remaining challenges involve healthy competition across the supply chain and the implementation of manufacturing best practices for large‑scale production.

For more information, visit Xaar.