The 3D printing landscape

From aerospace engines to mascara brushes, 3D printing is driving change in virtually every industry

Companies have used 3D printing for almost 30 years to make accurate and repeatable rapid prototypes and models to support the product design and innovation process. However, it is only within the last decade that we have seen the technology transition out of the prototyping lab and into the wider world of manufacturing.

In the automotive industry, 3D printing is helping to streamline the production and assembly process, with leading automotive companies such as BMW and Volkswagon reducing costs by 3D printing manufacturing and assembly jigs and fixtures rather than relying on conventional high-cost machining or turning to tooling suppliers.

The aerospace industry has been a long-standing user of additive manufacturing, primarily focused on developing and certifying 3D printed parts to improve the engineering of airframes and engines. In the last several years, the usage of 3D printed parts on aircraft has increased dramatically thanks to new aerospace-grade materials and intensive R&D work. Today, Airbus, GE Aviation, Rolls Royce, and other major aerospace players are integrating 3D printed parts into their new airframe and engine designs, a trend that will continue to grow in future designs. One common assumption is that 3D printing is limited to lowvolume manufacturing due to printing speeds and part costs. But numerous companies are disproving this theory.

In the consumer goods industry, Adidas is using 3D printing to mass produce a new line of footwear with printed lattice midsoles. In the luxury cosmetics industry, Chanel is 3D printing a novel design of mascara brush, with one million units printed a month.

Within the medical industry, mass customization comes in the form of 1.6 million patient specific 3D printed dental aligners a week, produced by Align Technologies, a leading medical device company, and one-off patient specific pre-surgical models used by Northwell Health to minimize risk and reduce time in surgery.

And in the services and aftermarket industry, 3D printing is used as a cost effective and agile method to source spare parts. Siemens Mobility is building a digital inventory of spare parts for rolling stock maintenance and Lufthansa Technik incorporates additive manufacturing within its aerospace maintenance, repair, and overhaul centers.

Graph Sources/ Wohlers Report 2019, 3D printing and additive manufacturing state of the industry.

Dimensional Research, Trends in 3D printing at scale.