Understanding Additive Manufacturing: Benefits, Challenges, and Future Prospects

March 31,2025

What is Additive Manufacturing (AM)?

Additive Manufacturing (AM), also known as 3D printing, is a revolutionary process for creating 3D objects. Unlike traditional manufacturing methods that involve subtracting material, AM builds objects layer-by-layer from a digital design. This approach allows for the creation of complex shapes and intricate designs that would be impossible with conventional techniques. AM uses a variety of materials, including plastics, metals, and even ceramics, to create working prototypes and end-use parts.

The Global Adoption of Additive Manufacturing

Research by Spherical Insights indicates that after more than 40 years of development, additive manufacturing is becoming more mainstream. The worldwide additive manufacturing industry is forecasted to expand from $19.9 billion in 2023 to $143.3 billion in 2033, representing a Compound Annual Growth Rate (CAGR) of 21.78%. However, the adoption of AM does not mean it is suitable for all manufacturers. The technology offers significant benefits when components are redesigned for additive processes, but this advantage is offset by the high costs of the technology and materials.

Implementing AM Technology

Implementing AM technology to simply switch existing component creations from conventional manufacturing methods is rarely advantageous. AM offers its largest benefit when components are tweaked and redesigned. However, this benefit is limited due to the high cost of the technology and compatible materials. For example, creating hollowed spaces to make components lighter is much easier to achieve using AM than with conventional methods that would require extra, complex steps.

Additionally, manufacturers often struggle to find a skilled workforce capable of applying 3D printing to real-world production. This is largely due to the somewhat new nature of the technology. This limited skilled workforce is just one reason why manufacturers need to carefully evaluate which of their applications would most benefit from AM.

Advantages of Additive Manufacturing

Reducing Energy Consumption in Manufacturing Industries

Among the numerous benefits of AM is the chance to reduce energy consumption by up to 25 percent. AM processes have the advantage of being more targeted in their energy use. They can focus solely on the material being built upon layer by layer.

As energy prices continue to climb across all sectors, AM offers a great chance for manufacturers to achieve cost savings. As well as the opportunity to become more environmentally friendly.

While the decrease in energy usage and waste is noteworthy, manufacturers are unable to completely benefit from it due to the restrictions of producing end-use parts on a big enough scale.

Reducing Waste

Beyond its potential for energy savings, there are other major environmental and economic advantages of additive manufacturing. A dramatic reduction in waste and material costs.

AM's layer-by-layer construction approach reduces material waste compared to traditional subtractive manufacturing methods. These methods involve removing material from a solid block to achieve the desired shape. According to studies, AM has the potential to achieve waste reduction of up to 90 percent. This, in turn, can lead to a massive decrease in raw material consumption.

Disadvantages of Additive Manufacturing

Higher Production Costs for Large Volumes

Industrial 3D printers have a huge initial start-up cost. This is anywhere from five thousand to hundreds of thousands in US dollars for just one machine. Alongside this, in 2011, Atzeni and Salmi conducted a study that revealed interesting findings. They discovered that the material costs for a specific metal part, when manufactured using traditional methods, amounted to €2.59 per part. However, the cost of the same part using selective laser sintering in AM skyrocketed to €25.81 per part. This means it would cost ten times more for manufacturers to use AM instead of traditional techniques. However, it is important to note that the material costs have likely decreased since this study was published. Also, the wider range of available materials might include cheaper options. However, despite these factors, the cost gap between AM and traditional methods still remains. If a plant's main goal is to reduce energy consumption, they may want to consider a more cost-effective alternative. One option could be to rethink their energy source, such as by installing solar panels. The cost of solar panels in the UK for 6kW panel systems can range from £9,500 to £10,500 for 24 panels, which covers 43 m² of roof space. Although, when sustainability is the priority, implementing solar panels might offer a faster return on investment (ROI). As well as, offering benefits that can be seen across the factory. While the environmental benefits of waste reduction are undeniable, the cost benefits are left to be desired. Manufacturers could still enhance their environmental consciousness and reduce material costs by adopting waste reduction methods. One such method is closed-loop manufacturing, which involves reusing materials used in production.

Slower Production Speed

AM technology is currently limited by its time and complexity constraints. Manufacturers may find AM technology largely beneficial for creating prototypes. Or, only useful in fields such as aerospace and medicine, where design manipulation is needed. With this factor taken into account, it would be far more beneficial for manufacturers to find other methods of energy cost reduction to save on costs. The slower speed of production also might cause manufacturers to have the opposite problem of streamlined supply and production. This is where overstocking is avoided, but the plant struggles to fulfill orders. The printing process for 3D objects might take anywhere from thirty minutes to several days. The larger and more complex the part, the longer it takes.

Conclusion: Is Additive Manufacturing Right for You?

While AM has many beneficial qualities, the technology is still in the early stages of usefulness to the general manufacturing industry. Until progress is made in the speed of the process and the cost of materials, other production methods might be better suited to applications where low-cost, time-efficient production is needed. On the other hand, the wider manufacturing industry might not benefit from this technology anytime soon. However, sectors such as aerospace, medical, and energy have already seen the benefits of AM. AM technology might not be what manufacturers currently need, but with progress, this will likely change. Manufacturers should carefully evaluate the specific needs of their operations and consider the potential benefits and drawbacks of adopting AM. As the technology continues to evolve and becomes more accessible, it may offer significant advantages that could transform manufacturing processes in the future.

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Understanding Additive Manufacturing: Benefits, Challenges, and Future Prospects

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