The term 3D printing still often brings to mind prototyping and small production runs, but the technology is advancing rapidly towards mass manufacturing. Though scaling is still a challenge, there are several instances of 3D printing used for large-scale production.
Additive manufacturing (AM) technologies are advancing and with this progress comes more innovative use cases. 3D printing’s capabilities are enabling manufacturers to produce better quality products more efficiently compared to traditional manufacturing methods. As 3D printing adoption increases in the manufacturing industry, there will be more opportunities to apply this technology to mass production operations.
Printing Payback
Production 3D printers are opening up new doors for manufacturers, enabling forays into mass manufacturing. These machines allow for more control over product designs and make capabilities like mass customization possible.
The benefits of 3D printing, including decreased lead times, increased efficiency, and design flexibility, are driving more manufacturers to adopt this technology and use it to complete large orders or production runs. There’s a lot of excitement around AM, but it can also create many boring, run-of-the-mill parts that manufacturers usually mass produce with traditional methods. These industrial parts may be mundane, but they’re necessary and 3D printers have the ability to mass manufacture them quickly while maintaining quality.
Despite the clear potential, manufacturers don’t always view AM as an option for mass production, especially if they have yet to implement the technology. 3D printing not only reduces manufacturing times but also enables manufacturers to create the same products with less material, reduced waste, and lower inventory levels. These advantages highlight more than just the capabilities of AM — they show the return on investment (ROI) manufacturers get from this technology.
Advancements in 3D printing technology are making adoption an imperative for manufacturers. Faster printing technology and increased material availability are resulting in 3D printed parts becoming commonplace and laying the groundwork for more mass manufacturing of AM products. Other 3D printing abilities such as lights-out manufacturing make it possible to use these machines for high production part runs, offering manufacturers even more flexibility.
Many manufacturers originally adopted 3D printing for prototyping and low-volume product runs. However, the significant ROI they’ve realized from implementing AM has led them to push the boundaries of what is possible with this technology.
Though many companies have not yet reached the level of true mass manufacturing, it is a regular occurrence for a business to need several thousand of the same part 3D printed per month, either in-house or through an AM service provider. Industrial use cases for 3D printed parts are rapidly increasing, leading to mass production manufacturing with AM technologies quickly becoming a reality.
Reaching for the Sun
While the manufacturing industry overall is increasingly using 3D printing for larger production runs, there are some specific examples of this in the industrial sector. There is untapped potential in the solar industry — with increased interest in solar panels and solar energy storage systems.
Currently, China, which accounts for 80% of global solar cell production, manufactures most of these products. However, American companies are exploring how to improve solar cell manufacturing and reshore the business. 3D Solar CEO Daniel Clark is taking a page from an old 2012 Massachusetts Institute of Technology (MIT) project that created “cube-shaped, 3D solar towers” that produced 20 times more power compared to flat-plate solar panels in the same location.
In 2012, the technology to actually mass manufacture these solar panels didn’t exist, but Clark has found a way to create a similar product with a hybrid 3D printing process. His company — 3D Solar — has created a micro bowl shape and inserted it into a solar panel’s structure. Similar to MIT’s prototype, this product captures more solar energy throughout the day, making it more reliable and efficient than other solar technologies.
3D Solar can quickly manufacture its solar module on a large scale using the company’s hybrid 3D printing process. This innovation leverages AM for mass production in a way that can spur future developments not only for solar technology, but also for other areas like quantum computing and micro-optics.
With mass manufacturing on the horizon for these solar panels, the company is able to make solar more cost-effective than current solutions on the market. As 3D Solar revolutionizes solar cell technology, this manufacturing company is also pushing the limits of 3D printing to new horizons.
Beyond Prototyping: The Key to Widespread AM Adoption
While innovative use cases like the solar cell exist and highlight how manufacturers can use 3D printing for mass manufacturing, there’s still work to be done to truly scale this technology in the industrial sector. Many manufacturing industries have fully adopted AM, but others still struggle to move beyond prototyping. Despite the benefits, there are barriers to overcome to achieve more 3D printing adoption in manufacturing. Manufacturers must resolve these challenges before more companies can take advantage of 3D printing for mass manufacturing.
Some of the most commonly cited challenges for adopting industrial 3D printing include the large initial financial investment, material availability, and the lack of qualified workers skilled in AM technologies. Additionally, many manufacturers have refrained from more seriously pursuing AM adoption due to the issues with scale. Some manufacturers are still skeptical about 3D printing’s usability as a large-scale production technology, especially when extensive post-processing is required.
To effectively combat these barriers, manufacturers — and the industry overall — need to focus more on training workers in AM technologies and hiring professionals who already have experience with additive and traditional manufacturing. Having these people on staff will help manufacturers more effectively adopt 3D printing. This is the key not only to wider adoption of AM across industries, but also to more use cases for large-scale production manufacturing.
Setting the Stage for Mass Production Manufacturing
Manufacturers are exploring how 3D printing can be used for mass manufacturing operations and continuing to push the limits of this technology. From innovative use cases to more mundane part production, AM is applicable to a wide variety of manufacturing endeavors.
Industrial companies need to invest more — both in AM technologies and workforce training — in order to effectively scale 3D printing in the manufacturing sector. As manufacturers continue to apply 3D printing more in their production operations, the industry is on the precipice of implementing AM for mass manufacturing and mass customization.
If you’re a manufacturer interested in 3D printing’s capabilities and want to see how you can use or expand it within your own operations, check out RAPID + TCT. Coming to Detroit from April 12-15, 2027, this is an additive manufacturing and industrial 3D printing event you won’t want to miss.