Additive manufacturing is revolutionising industry worldwide and presenting decision-makers with new opportunities. 3D printing technology is growing much faster than previously expected and is fundamentally changing production processes.[1] Companies that adopted this technology early on are reporting significant savings. At the same time, completely new business models are emerging. However, many managers do not know how to strategically utilise 3D printing technology. This article shows concrete ways.
Why 3D printing technology is becoming relevant now
The market for additive manufacturing processes is expanding rapidly. The annual growth rate is around 24.3 per cent until 2030.[3] This is significantly higher than in many traditional industries. However, companies in Germany are lagging behind. Only 9.4 per cent of additive manufacturing companies worldwide are based in Germany[5], which means that now is the perfect time to act.
Why should you as a decision-maker take notice? The answer lies in three factors: cost savings, flexibility and innovation. 70 per cent of companies were already printing more parts in 2023 than in the previous year[1]. But it also shows that the majority of companies have not yet fully understood this development.
Practical fields of application for 3D printing technology
3D printing technology is no longer just interesting for prototypes. Although 68 per cent of companies still use it mainly for prototyping,[8] this is changing rapidly. The following industries are already benefiting massively:
Automotive industry: Light and stable components
The automotive industry uses 3D printing technology for several purposes. It produces prototypes, tools and even end products. This saves considerable time and costs.[2] One major advantage is that printed parts are lighter. This improves fuel efficiency. At the same time, complex shapes can be realised that would be impossible using traditional methods.
Practical example: A leading car manufacturer uses 3D printing technology for interior components. This reduced the development time by 40 per cent. Spare parts are now also manufactured digitally and produced locally as required[4], eliminating expensive warehousing.
Aerospace: precision and lightweight construction
The aerospace industry relies heavily on 3D printing technology. Fuel tanks, engine components and other critical parts are produced here.[4] The requirements are extremely high. Tolerances may only be in the micrometre range. Nevertheless, additive manufacturing enables massive cost savings here.
An aerospace company is now printing complex brackets for aircraft systems. Production takes days instead of weeks. Material is saved by up to 60 per cent. This not only makes economic sense, but is also ecologically relevant.
Medical technology and healthcare
The medical industry is cited as the sector with the greatest potential for 3D printing technology[1] - and for good reason. Doctors need customised implants, prostheses and dentures. With 3D printing technology, customised solutions are created for each patient. This significantly improves treatment outcomes.
A dental laboratory uses 3D printing technology for crowns and bridges. The production time fell from two days to two hours. Quality increased at the same time. Patients receive their dental prostheses faster. This is a real differentiator on the market.
Mechanical engineering: Complex components efficiently
In mechanical engineering, 3D printing technology significantly reduces the manufacturing costs for complex components.[2] The investment amortises quickly, especially for small to medium quantities. Tool costs are eliminated. Production time is dramatically reduced.
A mechanical engineering company traditionally produced pump parts using injection moulding. This required expensive moulds. These costs were eliminated with 3D printing technology. At the same time, the design could be optimised. Weight was reduced by 30 per cent with the same performance.
Strategic opportunities for managers
Revolutionising supply chains with 3D printing technology
The traditional supply chain could change fundamentally. Instead of producing and transporting globally, parts could be printed locally[5], saving transport costs and time. At the same time, it reduces dependencies on distant suppliers. This is particularly attractive after the crises of recent years.
A large industrial group is already testing decentralised production. With 3D printing technology, spare parts are produced where they are needed. This means that factory downtimes are significantly reduced. Availability increases. At the same time, long delivery routes are eliminated.
Individualisation as a competitive advantage
3D printing technology enables individualisation without a price premium. Customers increasingly want personalised products. This is expensive and time-consuming with traditional methods. With additive manufacturing, it becomes economical.
A jewellery manufacturer uses 3D printing technology for customised pieces. Customers design online and the jewellery is printed a few days later. Upselling works better. Customer loyalty increases. That is real added value.
Sustainability and resource conservation
3D printing technology significantly reduces waste products. Traditional milling produces up to 90 per cent waste. With additive printing, it is minimal. This not only makes economic sense, but is also ecologically sound.
An aviation company saves hundreds of tonnes of material every year thanks to 3D printing technology. This reduces raw material costs and improves the carbon footprint. At the same time, the brand benefits: sustainability attracts customers and investors.
Challenges and realistic prospects
Not everything is euphoria. 3D printing technology also has its limits. Materials and costs are not yet competitive for all applications.[5] Many prints require post-processing. Quality standards need to be established. But these problems are being solved.
Artificial intelligence will play a key role. Automatic print optimisation, improved slicer software and AI-generated CAD will simplify the technology.[1] Design for additive manufacturing will be revolutionised by topology optimisation.
One important point: multi-material printing will become massively more important. Almost a third of the industry sees this as the greatest future influence[1], opening up completely new possibilities for complex components.
What decision-makers should do now
Step 1: Identify potential
Take a look at your production. Where do you have long delivery times? Where are expensive tools required? Where are transport costs high? These are potential areas of application for 3D printing technology. An honest inventory is the first step.
Step 2: Start pilot projects
Choose a manageable project. Perhaps spare parts or prototypes. You can test quickly with 3D printing technology. Results provide concrete data. ROI becomes measurable.
A medium-sized company started with tools. The results were impressive. He then rolled out 3D printing technology to several areas. The investment was amortised in 18 months.
Step 3: Build up expertise
Train your team. 3D printing technology requires a different way of thinking. Design must be done differently. Processes need to be restructured. The transformation works faster with competent employees.
Step 4: Enter into partnerships
You don't have to do everything yourself. Service providers with 3D printing technology can provide support. External experts help with strategy and implementation. This significantly reduces risks.
Different sectors, different opportunities
3D printing technology does not offer the same opportunities everywhere. In the automotive industry, the focus is on lightweight construction and cost reduction. In medical technology, the focus is on customisation. In aerospace, the focus is on precision and reliability.[4] Each industry must develop its own strategy.
The consumer goods industry is only just discovering the possibilities. Personalised products, faster market launches and better customer experiences are possible.[3] Those who act quickly here have a competitive advantage.
In the construction industry, 3D printing technology could produce houses and bridges.[7] It sounds like science fiction, but it is becoming reality. Modular, fast, cost-effective - these are the new standards.
The role of artificial intelligence
AI and 3D printing technology reinforce each other. Automatic print optimisation makes processes more efficient. Improved slicer software reduces errors. AI-generated CAD develops optimised designs[1] These synergies are far from exhausted.
Expect massive progress in the next few years. Non-planar prints will become standard. Design processes will be fully automated. Quality control through computer vision will be established. The technology will be democratised - even smaller companies will be able to use it.
Germany in an international context
Germany has strengths in the metal industry.[5] That is a basis. But it is not enough. The USA and Japan are leading the way. Germany risks losing touch. That's why the German government is investing millions in the Industry 4.0 initiative, but it needs to move faster.
Decision-makers should not wait for politicians to act. Anyone experimenting with 3D printing technology now has a head start in terms of experience. That is crucial. First movers have a competitive advantage. They know pitfalls. They have best practices. They can scale faster.
BEST PRACTICE at the customer (name hidden due to NDA contract)A large industrial company from Baden-Württemberg introduced 3D printing technology in three departments in parallel. It was ambitious, but it paid off. After 24 months, the company was saving 2.3 million euros a year. At the same time, the time to market for new products was reduced by 35 per cent. Employee satisfaction increased because routine tasks were eliminated and creative work increased. This shows that 3D printing technology is not just about reducing costs. It is transformation.
Financial profitability and business case
Profitability depends on the use case. With prototypes, the investment is often amortised in months. For spare parts, it takes longer, but it is safe. For series production of complex parts, it can take 12-24 months,[12] but then the advantage is permanent.
Think long-term. 3D printing technology is not just a question of cost. It's about speed, flexibility and competitiveness. Companies that understand this will be future-proof. The others fall behind.
Deutsch 
English (UK)