Additive Screen Printing: Scalable Production Meets Micro Precision
•February 19, 2026
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Why It Matters
ASP offers manufacturers a cost‑effective alternative to molds and powder‑bed AM for high‑volume, fine‑detail parts, opening new opportunities in heat exchangers, medical devices, and electronics.
Key Takeaways
- •Screen‑based additive printing creates thousands of parts per pass
- •Wall thicknesses reach 75 microns; internal channels 125 microns
- •Tooling cost far lower than injection‑mold tooling
- •Build rates up to 10,000 cm³ per hour
- •Compatible with metals, ceramics, polymers, and biomaterials
Pulse Analysis
Additive Screen Printing bridges the gap between traditional screen printing and modern additive manufacturing, delivering a surface‑based approach that sidesteps many of the handling challenges of powder‑bed processes. By pushing a material paste through a finely patterned screen, ASP can define geometry in the X‑Y plane while layer thickness is controlled vertically, allowing engineers to build complex, high‑resolution parts without the need for expensive powder handling or post‑processing steps.
The material palette of ASP is unusually broad, encompassing stainless steel, copper, aluminum oxide, zirconia, aluminum nitride, and a range of polymers and biomaterials. After each thin layer is cured with infrared or UV energy, the part is sintered, achieving over 96 % density and wall thicknesses as thin as 75 µm. These specifications make ASP ideal for heat‑exchange components, micro‑fluidic channels, and lightweight structural parts where thermal conductivity and mechanical strength are critical. The ability to embed closed internal channels directly during printing eliminates assembly, reducing part count and improving reliability.
From a production standpoint, ASP’s scalability stems from its reliance on screen tooling rather than custom molds. Screens can be fabricated in days and swapped quickly, keeping tooling costs low. Throughput is dictated by screen area, not part complexity, with systems capable of processing up to 40 carriers simultaneously and delivering 10,000 cm³ per hour. This translates to tens of thousands of micro‑precision components per shift, positioning ASP as a compelling solution for industries seeking high‑volume, high‑detail manufacturing without the capital intensity of traditional molding or the slower build rates of conventional 3D printing.
Additive Screen Printing: Scalable production meets micro precision
Additive Screen Printing is drawing attention as a technology to manufacture micro precise components made of metals, ceramics and many various other materials at scale. The advantages of additive manufacturing combined with industrial screen printing enables engineers to create complex parts that demand both, fine detail and high throughput.
Additive Screen Printing utilises a surface-based method. This allows for the simultaneous production of thousands of micro-precise components in a single production step, independent of the individual part geometry.
How the printing process works
The process builds parts layer by layer using a material paste. A squeegee pushes the paste through a precision screen, transferring the design onto a workpiece carrier. The screen defines the geometry in the X and Y axes, while the vertical movement sets the layer thickness.
Each layer is briefly dried or cured with infrared or UV light before the next layer is applied. Screens can be exchanged mid-process to create internal features such as channels or cavities. This means enclosed structures can be printed directly, without additional assembly.
After printing, the green parts are removed and sintered. During sintering, the binder burns out, and the metal or ceramic particles fuse into dense, functional components. Because the material is applied only where needed, there is no loose powder to handle.
Materials and ultra-fine structures
Additive Screen Printing works with a wide range of metals and ceramics, including stainless steel (316L), pure copper, aluminum oxide (Al₂O₃), zirconium oxide (ZrO₂), aluminum nitride (AlN) and many more. Polymers, porous and customized materials – or even biomaterials – can also be processed.
The process achieves wall thicknesses as thin as 75 microns and internal channels starting at 125 microns. After sintering, components reach over 96% density, suitable for demanding mechanical and thermal applications. A standout feature is the ability to integrate closed internal channels directly into parts, useful for heat exchangers, cooling structures or similar parts.
Efficient scaling of production volume
The process differs from injection molding and subtractive methods, as the main tooling is the screen, which can be produced in just a few days and is cheaper than traditional molds. Throughput is determined by screen area, not part count, with a single squeegee pass covering the entire surface. The production systems can circulate up to 40 workpiece carriers, reaching build rates of 10,000 cm³ per hour.
For example, ceramic wire guides measuring 6.2 × 3 × 1.4 mm can be produced at 84,000 units in an eight-hour shift. Output scales with screen area, not part complexity, making high-volume production feasible without compromising details.
Why you should get informed about Additive Screen Printing
Additive Screen Printing offers a scalable way to produce micro-precision parts while maintaining production speed. By combining additive design freedom with efficient industrial workflows, it provides a practical route for manufacturing complex metal and ceramic components.
Find out more about the technology on the Exentis Group website.
About Exentis Group
Exentis Group owns a unique additive screen printing technology platform that is able to handle large-scale production, both for industrial applications and in cleanroom settings.
Using the technology, it is very easy to manufacture components with wall thicknesses smaller than the diameter of a human hair and the technology is capable of processing almost any material.
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