Additive Manufacturing Explained: Technologies, Types & Trends

Written by: Lisa Bergstrom

Additive manufacturing, often known as 3D printing, is revolutionizing industries by transforming designs into tangible products with unparalleled precision. Since its inception in the late 20th century, this technology has rapidly evolved into a pivotal force in manufacturing, continually revealing new possibilities.

Manufacturers in highly regulated industries are navigating a perfect storm of supply chain disruptions, extended lead times and growing compliance mandates. Traditional production methods often struggle to keep pace with demand for rapid prototyping, lightweight parts and on-demand replacement components.

Additive manufacturing offers a compelling alternative, enabling greater design freedom, reducing material waste and supporting traceability from design to delivery. For regulated industries like aerospace and defense (A&D), it’s not just about innovation - it’s about staying mission-ready, cost-effective and compliant.

This article explores the essential principles that drive additive manufacturing, examining its modalities, materials and challenges, while highlighting its transformative role in several key industries.

Key Takeaways

• Mission-ready manufacturing: Additive manufacturing delivers lightweight, complex aerospace & defense parts faster, with full traceability to meet AS9100, ITAR, and other compliance standards.
• Digital-first agility: Layer-by-layer production cuts lead times, reduces waste, and enables rapid prototyping without costly retooling.
• Integrated control: ERP and QMS integration ensures real-time quality checks, material tracking, and audit-ready documentation across the manufacturing lifecycle.

In This Article:

• What is Additive Manufacturing?
• History and Evolution of Additive Manufacturing
• Types of Additive Manufacturing Technologies
• Materials Used in Additive Manufacturing
• Industries that Use Additive Manufacturing
• Challenges Inherent in Additive Manufacturing
• The Role of Integrated Digital Solutions in Additive Manufacturing
• Future Trends In Additive Manufacturing
• Frequently Asked Questions

Additive manufacturing (AM) is a digital-first production method that builds parts layer by layer from a 3D model. Unlike traditional subtractive manufacturing, which removes material from a solid block, additive manufacturing enables the creation of intricate geometries, lightweight structures and customized parts without the cost or constraints of tooling.

For QA, shop floor and ERP leaders, additive manufacturing represents more than just a new fabrication technique. It is a fundamental shift in how manufacturing is planned, executed and validated.

Every layer added is traceable, every design iteration is digital, and every build can be adjusted without physical retooling. This makes additive manufacturing especially valuable in regulated sectors, like Aerospace & Defense, where precision, repeatability and compliance with standards like AS9100 and ITAR are critical.

The process is inherently agile. Manufacturers can transition from concept to final part in days rather than weeks, producing components on demand to reduce lead times and inventory waste. Because additive manufacturing workflows integrate with modern ERP and quality management systems, organizations gain real-time visibility into quality checks, material usage and version control. These capabilities are essential in high-mix, low-volume and regulated environments.

Additive manufacturing is not just about printing parts. It is about rethinking the entire manufacturing lifecycle from design and prototyping to production and post-processing, with digital control and operational flexibility at the core.

The genesis of additive manufacturing can be traced back to the early 1980s when Charles Hull, an American engineer at 3D Systems Corporation, invented the stereolithography process. This marked the beginning of a transformative era in manufacturing, allowing the translation of digital designs into tangible product models. During this period, the primary use of additive manufacturing was rapid prototyping, enabling industries to produce scale models swiftly without the cost and complexity of traditional manufacturing methods.

From these early developments, additive manufacturing has evolved into a versatile manufacturing process with extensive industrial applications. No longer confined to prototyping, it now supports the creation of end-use products, revealing opportunities for customization across various sectors. This evolution from a niche prototyping tool to a mainstream manufacturing process underscores the dynamic potential of additive manufacturing in meeting the modern production demands inherent in Industry 4.0, also known as the Fourth Industrial Revolution (4IR).

Happening now, this latest revolution is driven by interconnectivity, automation, machine learning and real-time data, essentially creating "smart factories" where machines and systems can communicate and collaborate with minimal human intervention.

In sectors like Aerospace & Defense, for example, additive manufacturing now supports rigorous certification requirements, full traceability and version-controlled design data - capabilities essential for meeting standards such as AS9100, DFARS and ITAR.

For defense contractors and DoD suppliers, additive manufacturing enables faster turnaround times for mission-critical components while maintaining the documentation and quality assurance required in highly regulated environments.

There are seven main additive manufacturing processes, each employing distinct methods to form objects.

Vat Photopolymerization

Vat photopolymerization is a sophisticated AM process that uses a light source to cure a liquid photopolymer resin into solid plastic parts.

The technique constructs models by curing the resin layer by layer, typically starting from the bottom and progressing upward as new layers are added.

Known for its high resolution and smooth surface finish, vat photopolymerization is particularly effective for creating prototypes of intricate designs, such as those needed in small, complex technology components.

Material Extrusion

Also referred to as Fused Deposition Modeling (FDM), material extrusion is the most widespread 3D printing technology among consumer-grade printers.

This method employs a continuous filament of a thermoplastic, such as polyetherimide (PEI) or acrylonitrile butadiene styrene (ABS), which is heated to its melting point and systematically deposited to form layers.

Material extrusion is currently prominent among industrial manufacturers. During printing, the print head navigates along the X and Y axes, while the build platform moves vertically to construct the object in layers.

This technique makes manufacturing economical due to its simple mechanics and relatively low material costs. Material extrusion is suitable for a wide range of non-complex applications where high detail isn't a critical factor.

Material Jetting

Material jetting is the harbinger of precision in AM, offering unparalleled surface smoothness for QA and ERP managers seeking high-fidelity prototypes and tooling. This technology operates by depositing microscopic droplets of liquid resin or metal via inkjet-style printheads, which are then solidified, typically with ultraviolet light or, for metals, with sintering - the process of forming a solid mass of material through heat and pressure without melting to the point of liquefaction.

The result? Exceptionally thin layers, sometimes less than 20 microns, yielding parts where layer lines are nearly invisible to the naked eye. Material jetting's multi-printhead systems unlock the ability to print with multiple materials and colors in a single build, making it ideal for complex assemblies. However, this precision comes at a cost: increased build times and higher machine expenses.

Binder Jetting

This AM process offers a compelling blend of speed, versatility and scalability. Binder jetting uses a printhead to selectively deposit a liquid binding agent onto layers of powdered material - metals, polymers or ceramics - building parts layer by layer. The unbound powder serves as a natural support, enabling complex geometries without the need for additional structures.

Once printing concludes, the "green" part undergoes post-processing, such as sintering, to achieve final density and strength. Binder jetting excels in producing parts with variable internal structures and can incorporate color, making it suitable for both functional and visual prototypes. Its room-temperature operation minimizes thermal distortion, and the process is generally faster than many alternatives.

However, parts often require significant post-processing to enhance mechanical properties, and the technology is less suited for high-load, structural applications. Binder jetting's flexibility makes it a strong candidate for rapid prototyping and low- to medium-volume production.

Sheet Lamination

Sheet lamination bonds thin layers of material, such as metal, paper or composites, which are then cut to shape. Techniques like Ultrasonic Additive Manufacturing (UAM) fuse metal sheets using ultrasonic welding, while Laminated Object Manufacturing (LOM) uses adhesives and cross-hatching for separation.

This process operates at lower temperatures, allowing for the fast and large-scale creation of parts. While not ideal for load-bearing parts, it’s useful for visual models or prototypes where speed and simplicity are key.

Directed Energy Deposition (DED)

DED is designed for building or repairing metal parts by melting wire or powder feedstock with a focused energy source such as a laser or electron beam. A multi-axis arm deposits material precisely where needed, making DED valuable for part repair or adding features to existing components.

Although complex, DED is used in aerospace for extending part life and enabling on-demand repair of high-value assets, particularly where conventional manufacturing is too slow or costly.

Powder Bed Fusion

This is an additive manufacturing process that uses a laser or other heat source to selectively fuse regions of a fine powdered material, which is spread in thin, even layers across the build platform.

Each layer is fused according to a 3D model before a new layer of powder is evenly distributed on top. This process allows for the precise creation of complex parts with minimal waste.

PBF supports a wide range of materials, including metals, plastics and ceramics. Techniques such as Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS) fall under this category, making it popular for high-performance applications where strength, accuracy and surface finish are critical.

Choice of material plays a key role in determining the appearance and functionality of a final product created by additive manufacturing. Each material category has unique advantages and applications.

Thermoplastics Such as PLA, ABS and Nylon

Plastics are among the most widely used materials in AM due to their affordability and ease of use. Common types of plastics used include thermoplastics such as polylactic acid (PLA), acrylonitrile butadiene styrene (ABS) and nylon.

• PLA is valued for its biodegradability and ease of printing, making it ideal for educational projects.
• ABS, known for its toughness and durability, is frequently used in industrial applications.
• Nylon's flexibility and strength make it a preferred choice for functional prototypes and components.

The adaptability of plastics allows designers to explore complex internal structures with minimal material waste.

Metals Like Titanium, Aluminum and Stainless Steel

Metals in AM present possibilities for creating robust, high-performance parts with exceptional mechanical properties.

• Titanium is renowned for its exceptional strength-to-weight ratio and biocompatibility, making it an ideal material for aerospace components and medical implants.
• Aluminum offers lightweight solutions critical in the automotive sector.
• Stainless steel provides corrosion resistance and durability for a variety of industrial applications.

Composites and Ceramics

Composites in AM include materials that combine two or more distinct substances to achieve superior performance. These materials are gaining prominence due to their ability to offer enhanced strength, reduced weight and tailored performance.

Common composites include carbon fiber-reinforced polymers, known for their exceptional strength-to-weight ratio, making them ideal for aerospace applications.

By incorporating continuous fibers within a polymer matrix, these composites provide unparalleled mechanical properties that are challenging to achieve with standalone materials.

Bioprinting Materials for Medical Applications

Bioprinting materials are redefining what's possible in medical manufacturing, offering a custom approach to regenerative medicine and drug development. At the core are bioinks—complex blends of living cells, extracellular matrices and hydrogels—engineered to mimic the intricate architecture of human tissues.

These materials meet stringent quality standards for biocompatibility, sterility and reproducibility, with each batch undergoing rigorous assessments of viscosity, pH and cell viability to ensure optimal performance in clinical and research settings.

Traceability is paramount: Every material batch is tracked from sourcing through production, creating a digital thread that supports regulatory compliance and audit readiness. Emerging applications: vascularized tissue constructs and dynamic scaffolds for bone regeneration.

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Now, companies can produce complex parts directly from digital models, without the need for traditional molds or machining processes. Firms are also experiencing transformative improvements in efficiency and innovation. Continuously, the AM process pushes the bounds of what's possible, making it a staple in modern production strategies.

Automotive

AM is redefining vehicle design, enabling greater design freedom and the production of lightweight components that enhance fuel efficiency. The ability to rapidly prototype 3D models facilitates faster design iterations, reducing time to market for new vehicle models.

Processes such as Selective Laser Melting and material extrusion enable the automotive industry to offer enhanced customization options without compromising sustainability.

Aerospace and Defense

AM technologies give the aerospace industry tools to produce lightweight and complex components, which are essential for reducing emissions. Materials such as titanium and high-performance polymers are frequently used to fabricate parts with specific mechanical properties, ensuring they withstand the extreme conditions experienced during flight. Also, the potential for on-demand manufacturing makes AM a cost-effective solution compared to traditional manufacturing methods, as parts can be economically made as needed.

AM also supports the aerospace sector’s strict compliance, documentation and traceability requirements.

With digital design records, version control, and full material history, manufacturers can align with standards such as AS9100 and ITAR, while improving visibility across the entire production lifecycle. This level of control is critical for audit readiness and maintaining quality across complex, high-stakes programs.

Healthcare and Bioprinting

The technology's ability to produce customized medical implants and prosthetics tailored to individual patient anatomies has revolutionized personalized medicine. Healthcare providers can now develop precise 3D objects from digital models, ensuring optimal fit and function. AM's layer-by-layer construction technique enables the use of biocompatible materials that enhance patient safety and recovery.

Additionally, AM supports the development of complex medical devices and surgical instruments, reducing production time and costs associated with traditional methods. Research in tissue engineering and bioprinting continues to expand, promising future innovations such as the creation of artificial organs.

Architecture and Construction

By leveraging advanced specification software solutions during the AM process, project teams can confidently translate visionary concepts into buildable realities while maintaining strict quality standards.

AM technology enables rapid prototyping and the creation of custom-building components, reducing lead times and minimizing waste.

For QA and ERP managers, this means streamlined workflows and greater control over material traceability, compliance and documentation. Robust reporting capabilities ensure that every detail—from project scope to product selection—is carefully captured, supporting transparent collaboration across stakeholders.

In defense and disaster response scenarios, AM also shows promise for rapidly deploying temporary or modular infrastructure in remote or high-risk environments.

Consumer Products and Electronics

In this sector, manufacturers can quickly iterate product designs, responding to market trends and customer feedback with astonishing speed—invaluable for leaders tasked with balancing innovation and regulatory compliance.

AM streamlines the transition from digital prototype to finished product, reducing inventory requirements and enabling on-demand production. The result is a more resilient supply chain and the ability to deliver highly customized products that delight consumers while upholding the highest standards of traceability.

Tooling and Industrial Applications

Manufacturers can rapidly produce complex tooling, jigs and fixtures tailored to the unique requirements of each manufacturing process. This not only accelerates time to market but also reduces operational costs.

Plus, the ability to quickly adapt tooling to new product lines or process improvements embraces a culture of continuous innovation.

While additive manufacturing offers distinct advantages over legacy manufacturing methods, it also presents unique hurdles:

Structural Integrity and Strength

AM can lead to anisotropic mechanical properties, meaning the strength and durability of printed parts can vary depending on the direction of their layers. Ensuring consistency and reliability requires careful material selection and process control.

Post-Processing Requirements

After the AM process is complete, most 3D-printed parts require post-processing to meet functional and aesthetic standards. Post-processing can involve several techniques, including surface finishing to remove imperfections, heat treatment to improve mechanical properties and machining to achieve precise dimensions. Consequently, post-processing can significantly affect the overall production timeline and cost.

Design for Manufacturability

Designing for manufacturability in the context of AM involves rethinking traditional design principles to leverage the unique capabilities of 3D printing technology, which led to the establishment of the Design for Additive Manufacturing (DfAM) approach.

While this shift can be challenging for teams accustomed to conventional methods, it also presents significant advantages. DfAM enables the creation of lighter, stronger parts with integrated features that reduce the need for fasteners, welds or subassemblies - ideal for applications where every ounce counts and failure points must be minimized.

Net/net: Many classic industrial designers need to unlearn traditional design methods and then relearn for success with AM.

Industry-leading enterprise resource planning (ERP) solutions and quality management systems (QMS) play a key role in unlocking the full potential of additive manufacturing, requiring tight coordination across engineering, production and quality functions.

Integrated manufacturing ERP and QMS platforms form the digital nerve center that connects these workflows, unifying design files, material usage, scheduling, compliance checks and post-processing activities.

In mission-critical industries like Aerospace & Defense, these systems are essential to meeting complex regulatory demands. From ITAR and AS9100 to DFARS and emerging CMMC requirements, compliance depends on traceability, secure data handling and real-time visibility.

ERP and QMS platforms help automate documentation, enforce approval workflows and maintain digital records that stand up to audits - all while supporting continuous improvement.

This level of integration is particularly critical in highly regulated sectors such as defense, where end-to-end traceability and version control are critical requirements for certification and risk mitigation.

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Additive Manufacturing is fast redefining the landscape for materials manufacturers, with a wave of innovations poised to transform how products are designed, produced and delivered. As global supply chains demand greater agility and quality standards continue to rise, AM is stepping into the spotlight—ushering in an era where customization, efficiency and sustainability are not just goals, but expectations.

One of the most compelling shifts on the horizon is the maturation of multi-material and hybrid AM processes. These technologies enable the fabrication of complex parts with diverse yet tailored properties—think components with both rigid and flexible zones—establishing new design freedoms and reducing the need for secondary assembly steps. This translates to more streamlined workflows and fewer points of failure, directly supporting robust quality assurance and compliance efforts.

Artificial intelligence (AI) and machine learning are becoming indispensable in the AM toolkit. By embedding AI into QMS platforms, manufacturers can optimize process parameters in real time and predict maintenance needs before issues arise.

Large-scale AM is scaling up, quite literally, with new systems capable of producing bigger, more complex metal and polymer parts for demanding applications in energy, transportation and beyond. Meanwhile, the medical field is witnessing breakthroughs in regenerative medicine, where patient-specific implants are moving from concept to clinic.

These advancements are particularly relevant in mission-critical programs that demand lighter, stronger and more reliable parts. Innovations such as hybrid materials, predictive AI and 4D printing will help reduce lifecycle costs, support real-time certification and improve supply chain resilience—all without compromising quality or traceability.

Finally, the emergence of 4D printing—where smart materials respond dynamically to environmental triggers—signals a future where products can evolve post-production, adapting to their surroundings.

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