REGINA — When you hear “3D printing,” you might picture a small machine on a desk making colorful trinkets. But in a lab at the University of Regina, that idea is being completely reshaped. Here, 3D printing isn’t just a hobbyist’s tool; it’s the foundation for building custom medical devices, pioneering sustainable housing, and engineering the future of high-performance industries.
Welcome to the Additive Manufacturing Research Lab (AMRL), the only dedicated 3D printing research lab in Saskatchewan. Led by Mohammad Khondoker, an assistant professor in the Faculty of Engineering and Applied Science, the lab is a hub of innovation where the boundaries of manufacturing are redrawn daily.
We’re not limited by what commercial systems can do; we create new capabilities. — Dr. Mohammad Khondoker, assistant professor, Faculty of Engineering and Applied Science, University of Regina
The AMRL advantage: More than a lab, an innovation engine
What makes the AMRL unique isn’t only its status as a provincial first, but also its hands-on philosophy. While most labs use commercial 3D printers as “black boxes,” hoping for the best, Dr. Khondoker and his students build and modify their own.
“We must understand and control every variable in the process,” says Khondoker, explaining that this “guinea pig” approach means that when industry partners bring unconventional materials or extreme requirements, the lab can redesign the printing process to accommodate them. “We’re not limited by what commercial systems can do; we create new capabilities.”
This spirit of innovation is what enabled Khondoker to build the research program from the ground up. Arriving at the University without a single 3D printer, he secured an NSERC Discovery Grant that provided the essential funding to establish and grow the first additive manufacturing-focused research lab in Saskatchewan.
Solving real-world problems
The lab’s innovations are not just theoretical; they are providing tangible solutions for healthcare and industry. One of the most impactful projects is the creation of custom-fit orthotics.
“Most traditional orthotics are ‘one-size-fits-all,’” says Khondoker. “We can design orthotics to match the specific needs of each person’s body.”
Using a specialized polymer, the lab recently 3D-printed an orthotic that feels as soft as flesh but is strong enough to support an injured hand. This personalized approach enhances comfort and mobility in ways standard devices cannot.
The lab is also a gamechanger for industries such as aerospace and automotive. The team has developed a new type of heat exchanger using metal 3D printing that outperforms traditional models while taking up less space. The breakthrough is its internal “lattice” structure, a 3D honeycomb impossible to create with conventional methods. This allows engines and cooling systems to operate more efficiently, reducing fuel consumption and emissions, a critical advantage in applications where weight and space are at a premium.
Students as innovators and entrepreneurs
The AMRL is a testament to the U of R’s commitment to experiential learning, where students are not just assistants but primary investigators.
“Each graduate student takes ownership of a unique research thrust,” Khondoker notes proudly, highlighting how students lead and thrive, fostering trust in the University’s commitment to nurturing future innovators.
Rawan Elsersawy, a PhD student in the lab, is a prime example.
“Working in this lab has allowed me to connect theory directly to practice,” says Elsersawy. “You are not just learning concepts in isolation. You are applying them, seeing where they succeed, and understanding where improvements are needed.”
Elsersawy is currently developing a large-format polymer 3D printer with unique capabilities that go far beyond what’s commercially available. Unlike most printers that rely on filaments, this system uses raw pellets and can print multiple polymers with complete blending control. It achieves extremely high print speeds, measured in kilograms per hour rather than grams, and features a custom-designed nozzle for exceptionally smooth surface finishes. The innovation has already led to the launch of a startup to commercialize the technology.
In fact, the AMRL has launched two spinoff companies led by graduate students: Hexergy Innovations Inc., which specializes in 3D-printed heat exchangers, and another, currently in the process of incorporation, that will commercialize next-generation polymer 3D printers, exemplifying how students translate research into industry impact and entrepreneurial success.
A catalyst for Saskatchewan’s bright future
While Saskatchewan may be seen as behind in advanced manufacturing, the AMRL’s work positions the province to become a future leader, inspiring optimism about regional growth and innovation.
“Our lab is well-positioned to contribute meaningfully,” says Khondoker. “For instance, through 3D printing research focused on critical Small Modular Reactor (SMR) components such as high-performing heat pipes. By advancing this work, we can help establish Saskatchewan as a pioneer in nuclear innovation.”
From custom-fit medical devices to more efficient industrial parts and a more sustainable future for the province, the work happening at the AMRL is a powerful example of how research at the U of R is solving real-world problems. It’s a place where students are not just preparing for the future; they are actively building it.
