What's New in Dragonfly 3D World 2027 for Additive Manufacturing
July 31, 2026
Additive manufacturing continues to push the limits of part complexity, but inspecting and validating those parts presents its own challenges. As CT datasets become larger and more complex, engineers need tools that keep pace with modern manufacturing workflows. Dragonfly 3D World 2027 is almost here, bringing new AI-powered analysis, advanced measurement capabilities, integrated reporting, and workflow improvements designed to help additive manufacturing engineers gain more from their CT data. Whether you're developing new materials, validating printed parts, or supporting production quality, the latest release is designed to streamline CT inspection across the additive manufacturing workflow. Here's a closer look at what's coming in the next generation of 3D World.
"Dragonfly 3D World 2027 is one of our most comprehensive releases to date. Rather than focusing on a single breakthrough, we've enhanced the platform from end to end so users can spend less time managing data and more time generating insights."
Zixiong Cao
Product Manager
1. Accelerate Instance Segmentation with AI
One of the biggest additions coming to 3D World 2027 is a new AI-powered instance segmentation workflow built on Meta AI's Segment Anything Model (SAM).
Instead of manually outlining individual objects or training a model before getting started, the workflow automatically separates every object it identifies in a 2D view with a single click. Each detected object is published as its own label, making it easy to count, measure, and analyze powder particles, pores, lack-of-fusion defects, support structures, lattice features, and other complex geometries commonly found in additive manufacturing datasets.
According to Zixiong Cao, Product Manager, one of the biggest advantages of the new instance segmentation workflow is how quickly it allows users to begin exploring their data.
“Instead of spending valuable time preparing data before analysis, users can begin identifying and measuring objects almost immediately,” he explains. “It lowers the barrier to AI-assisted segmentation while still giving researchers the flexibility to refine their approach as needed."
2. Analyze Porosity and Internal Defects with Subvoxel Multi-Mesh
Subvoxel Multi-Mesh is another standout feature included in the new release. Available with a Full License, it enables repeatable, subvoxel-accurate porosity analysis for more detailed component measurements.
Instead of treating an object as a single mesh, the software can split connected components into individually labeled meshes. Each pore, void, phase, or feature can then be measured independently with greater geometric accuracy.
Since meshes follow curved surfaces more precisely than voxel-based regions of interest, users can generate more accurate results for porosity analysis, defect characterization, phase analysis, and more, while maintaining consistent, repeatable outcomes across datasets.
Scott Eckley, Technical Sales Manager, describes Subvoxel Multi-Mesh as an important step forward for quantitative analysis. "It allows us to characterize complex structures with a level of precision that wasn't previously possible in many applications.”
He adds, “For researchers working with porous materials or advanced manufacturing, that's a meaningful advancement."
Whether you're validating printed components, characterizing internal porosity, optimizing process parameters, or performing manufacturing quality control, Subvoxel Multi-Mesh provides a more detailed view of complex internal structures.
3. Work More Efficiently with New Mesh and CAD Tools
Dragonfly 3D World 2027 introduces a range of new mesh editing and CAD interoperability tools, making it easier to inspect, compare, and prepare complex 3D models for analysis.
New capabilities include:
- Boolean mesh operations (Union, Intersection, Difference, and XOR)
- Automatic mesh registration for scan-to-CAD alignment
- STEP CAD import
- Support for additional mesh file formats
- Faster remeshing and mesh optimization
These additions simplify reverse engineering, scan-to-CAD comparison, dimensional inspection, and mesh preparation. By reducing manual preprocessing and improving interoperability with CAD software, 3D World 2027 helps users move from imported models to analysis more quickly.
4. Build Reports Without Leaving 3D World
Report Builder is a new feature that transforms 3D World into an end-to-end analysis and reporting environment, making it easier to document and share results without switching between applications.
As Jana El Bsat, Training Product Manager, shares, "Every version of Dragonfly brings something unique. Each release reveals new capabilities that empower users to do more. With this version, we’re closing the loop, taking users from data exploration through to reporting. Our users spoke, and we listened."
Rather than exporting screenshots, measurements, and statistics into external software, users can create reports directly within 3D World using an intuitive drag-and-drop workflow.
Reports can include:
- Interactive images and visualizations
- Measurements and statistics
- Histograms and profiles
- Object properties
Report Builder includes PDF and HTML export, while Full License users also gain editable Microsoft Word export, customizable headers and footers, and embedded 3D surface meshes.
Eckley notes, "Researchers invest significant time generating high-quality results, but communicating those findings can still require several manual steps. Report Builder brings analysis and reporting together in one environment, making it easier to create professional, consistent documentation."
Whether documenting research findings, preparing quality assurance reports, or creating client deliverables, Report Builder improves one of the final (and often overlooked) steps in the analysis process.
5. Speed Up Object Separation with Fast Split
Separating touching objects is often one of the most time-consuming parts of image analysis. With Dragonfly 3D World 2027, the new Fast Split tool dramatically reduces the time required.
Powered by Dragonfly's GPGPU framework, Fast Split separates connected objects in seconds, providing a fast, one-click alternative to traditional watershed segmentation. Working alongside the new Smart Erode tool, it preserves important object boundaries while efficiently separating powder particles, pores, lattice structures, support remnants, and other touching features found in additive manufacturing CT datasets.
By dramatically reducing processing times on large datasets, Fast Split helps accelerate segmentation without compromising accuracy or reliability.
6. Explore Every Angle with Rotational Views
Some structures are difficult to evaluate from a single cross-section, especially components such as batteries, pipes, fibers, and other round geometries. 3D World 2027 introduces Rotational Views, allowing users to inspect these features from every angle without constantly repositioning the dataset.
Rather than manually rotating the volume to create multiple slice orientations, users can re-slice the XZ view around the object's axis, providing a continuous view of the structure as the slice rotates it around. This makes it easier to examine features that wrap around curved surfaces or identify defects that may only be visible from certain angles.
7. Visualize, Measure, and Communicate Results More Effectively
Dragonfly 3D World 2027 introduces a collection of new visualization, annotation, and measurement tools to make workflows more intuitive.
New annotation capabilities include the Caliper tool for measuring perpendicular distances between surfaces and Scalar Arrow annotations that display measurements directly within 2D and 3D views. Users can also automatically generate rulers along a path, create smooth RBF surfaces from point annotations, and create referential coordinate systems for more consistent positioning, measurements, and comparisons across datasets.
Visualization has also been enhanced with improved mesh rendering modes, camera bookmarks that preserve complete scene settings (not just the camera position) to create reproducible figures and presentations, and new minimal and oriented bounding box (OBB) clip boxes that improve visual inspection of complex parts.
These new capabilities help users inspect complex datasets, present findings more clearly, and create consistent visual outputs across projects.
8. Measure Surface Roughness Directly from CT Data
Surface finish plays a crucial role in additive manufacturing, influencing everything from mechanical performance to post-processing requirements. Dragonfly 3D World 2027 introduces Surface Roughness Analysis, enabling users to measure surface texture directly from CT-derived meshes at a standard comparable to traditional stylus-type surface roughness instruments.
Instead of relying on traditional contact profilometers (which often can't access internal or complex geometries), users can now perform both profile (1D) and areal (2D) surface roughness measurements non-destructively, making even the most challenging surfaces easier to inspect.
Ideal applications include:
- Additive manufacturing quality assurance
- Machined component inspection
- Tribology studies
- Surface finish certification
- Internal surface analysis
To support these new workflows, the Surface Determination tool has also been redesigned with histogram-guided thresholding, optimized mesh generation for roughness analysis, and full macro compatibility for repeatable automated processes.
9. Discover New Features Available with Full Licenses
Dragonfly 3D World 2027 introduces a new category of features available exclusively for Full Licenses, expanding access to advanced analysis, reporting, and productivity tools for commercial users.
New Full License features include:
- Subvoxel Multi-Mesh for repeatable, subvoxel-accurate porosity analysis
- Surface Roughness Analysis for advanced mesh-based surface measurements
- Additional Report Builder capabilities, including editable Microsoft Word export, customizable headers and footers, and embedded 3D surface meshes
- The ability to export ORSObject and ORSSession files that can be shared with anyone using the free Project Viewer
Users with an Academic License (formerly known as FreeD) will be able to download 3D World 2027 when it's available. While features exclusive to Full Licenses will remain visible within the interface, they’ll appear grayed out and inaccessible under an Academic License.
10. Share Results More Easily with Project Viewer
Another upcoming addition to Dragonfly 3D World 2027 is Project Viewer, a free application that will make it easier to share your work with customers, colleagues, and more.
For the first time, you'll be able to share and open Dragonfly ORS Object and Session files without requiring the full version of 3D World. Project Viewer will provide an interactive way to explore results and collaborate across teams, making it easier to share findings with stakeholders who don't have a full software installation.
Project Viewer will be available as a separate download later this year.
Get Ready for Dragonfly 3D World 2027
Dragonfly 3D World 2027 represents the next evolution of the platform, bringing together AI-powered segmentation, advanced measurement capabilities, mesh analysis, and workflow enhancements designed to support today's most demanding additive workflows.
Lead Global Digital Marketing Manager Alexander Lossa summarizes the release well, "What excites me most about Dragonfly 3D World 2027 is how the improvements build on one another. Individually they're powerful, but together they create a smoother, more connected experience from data exploration through reporting.”
The new software will be available to download soon, with a planned release in early autumn/fall. In the meantime, follow us on Instagram and LinkedIn as we share more feature highlights and launch news in the coming weeks.
If you're a Full License user already, now is a great time to review your Dragonfly Support Plan. An active Support Plan ensures you'll be ready to access Dragonfly 3D World 2027 as soon as it's available. Contact our team to review your coverage and prepare for the upcoming release.
Can't wait to try Dragonfly 3D World?
The new release may be coming soon, but there are a host of exciting features, analyses and options to explore with the current version. Why not try it out today with a free 30-day free trial?