Additive Manufacturing: Three Strategies to Stay Ahead

Additive manufacturing, or AM, is transforming product design and production. By enabling complex geometries and highly customized components, AM offers capabilities that traditional manufacturing cannot match. To succeed in this field, it’s essential to understand its nuances and apply best practices. Here are three strategies to help you stay ahead.

1. Choose Smart, Choose Sustainable

Material selection is a cornerstone of successful additive manufacturing. The right material affects performance, durability, cost efficiency, and environmental impact.

When choosing materials, assess the specific needs of your project. For components that must be lightweight and strong, titanium or high-strength polymers are often ideal. For applications requiring flexibility, thermoplastic elastomers may be a better choice.

For example, aerospace parts often use titanium for its strength-to-weight ratio, which enhances performance and fuel efficiency. Custom prosthetics, by contrast, benefit from polymers that can be tailored for comfort and fit.

Printer compatibility is another key consideration. Not all 3D printers support every material. Research your equipment’s capabilities to ensure your material choices align with your manufacturing goals.

Manufacturing a new component

2. Optimize Your Design for Additive Manufacturing

Designing for AM differs from traditional manufacturing. The freedom offered by 3D printing allows for intricate structures previously impossible to create.

Take advantage of this flexibility. Incorporating lattice structures can reduce weight while maintaining strength. Designing components as a single printed unit can simplify assembly and reduce potential failure points.

Print orientation also matters. The angle at which a part is printed can influence strength and surface finish. A vertical orientation may yield stronger parts, while a horizontal orientation could improve surface detail. Experiment with different orientations to find the optimal setup for your design.

3. Invest in Post-Processing Techniques

While additive manufacturing produces high-quality parts, post-processing is often essential to achieve the desired finish and performance. Techniques can include sanding, polishing, or heat treatment, depending on the material and application.

Effective post-processing enhances both aesthetics and functionality. Surface finishing reduces friction and can improve mechanical properties, while heat treatment can increase durability under extreme conditions. Consider the cost and time of post-processing early in your planning to manage resources and timelines effectively.

The Road Ahead: Hybrid and Distributed Manufacturing

Additive manufacturing is not just a tool—it’s a mindset. Understanding materials, optimizing design, and investing in post-processing unlock its full potential. Emerging trends such as hybrid manufacturing and distributed production are reshaping global supply chains and increasing manufacturing resilience.