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Sanjay Gangal
Sanjay Gangal
Sanjay Gangal is the President of IBSystems, the parent company of, MCADCafe, EDACafe.Com, GISCafe.Com, and ShareCG.Com.

AON3D: Revolutionizing 3D Printing with Metal Replacement Polymers

July 1st, 2024 by Sanjay Gangal

In the ever-evolving landscape of additive manufacturing, AON3D stands out as a pioneering force. Founded in 2015, this Montreal-based company has made significant strides to make it easy and affordable to 3D print the world’s highest performance polymers, also known as metal replacement polymers. In a recent conversation with Eric Beardslee, Product & Content Marketing Manager at AON3D, we delved into the innovative solutions and applications that are propelling the company to the forefront of the industry.

AON3D’s Vision and Mission

AON3D’s mission is clear: to democratize industrial 3D printing by providing open material printers that allow users full control over the entire process. Beardslee explained that the founders were frustrated with the status quo, where proprietary systems limited users to specific settings and materials. This motivated them to create a printer that offers unparalleled flexibility and control with end-to-end automation for those who want “just push print usability”.

“We are a hardware and software company that focuses primarily on metal replacement polymers,” Beardslee stated. “We’re working towards AM adoption in regulated applications through process automation, AI-drive process tuning, and in-process monitoring, which delivers stronger, more consistent, and quality verified parts.”

Cutting-Edge Hardware: The Hylo High Temperature 3D Printer

The Hylo High Temperature 3D Printer

At the heart of AON3D’s hardware offerings is Hylo, one of the largest and fastest high temperature 3D printers on the market, is able to process the world’s highest performance polymers, such as PEEK and ULTEM™. With a build volume of 650 x 450 x 450 mm and independent dual extrusion, Hylo can produce full scale, end-use parts in a fraction of the time. 

“Our printer has end-to-end automation,” Beardslee said. “It features an automated material system, optical nozzle inspection and XY calibration, independent extruder leveling, and in-process monitoring. Through automation, we can achieve new levels of reliability and part consistency”

Applications Across Aerospace and Defense

AON3D’s technology is already making an impact in critical industries such as aerospace and defense. Parts printed using AON3D’s solutions are on rockets, the International Space Station, and even on missions to the Moon.

“A lot of our customers are in aerospace, defense, and factory floors,” Beardslee noted. “They choose our solution because it offers the flexibility to use open materials, which are affordable and allow customers to recoup their investments in months, not years.”

AI-Driven Additive Manufacturing Optimization Software: AON3D Basis™

The hardware is only one part of the equation. AON3D’s software, Basis™, leverages artificial intelligence to optimize the printing process. This AI-driven software tunes process parameters based on the material and thermal profile of each part, ensuring consistent quality and maximized part strength.

“Our software analyzes orientation, geometry, and even maps the build volume’s convective flows,” Beardslee explained. “By tuning process parameters alone, we’ve been able to achieve up to 65% stronger parts.”

Open Materials and Metal Replacement Polymers

AON3D’s open material approach is a significant departure from the proprietary systems that dominate the market. This openness allows users to experiment with and utilize a wide range of materials, including advanced polymers that can replace metals.

“We validate materials from the best vendors and white label them for our customers,” Beardslee said. “Material development is where much of the industry growth is going to be. For example, one of our users is testing a polymer that offers comparable strength to 6061-T6 aluminum, but 50% of the weight.”

Customer Support and Future Growth

AON3D prides itself on its customer-centric approach. The company’s applications team works closely with clients to recommend materials, ensure successful implementation of their technology, and even develop print profiles on request.

Looking ahead, AON3D is poised for significant growth. The company recently moved to a larger office, is currently increasing production, and is nearly sold out into the next year. As they continue to ramp up, their focus remains on refining their software and expanding their material offerings.


AON3D’s innovative approach to 3D printing is reshaping the industry. By combining advanced hardware, AI-driven software, and an open materials philosophy, they are enabling customers to achieve new levels of performance and efficiency. As they continue to grow and innovate, AON3D is set to play a crucial role in the future of additive manufacturing.

For more information about AON3D and their cutting-edge solutions, visit or contact their sales team at

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Category: 3D printing

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