This article will answer the following questions:
What is additive manufacturing and how does it work?
What are common applications of additive manufacturing?
What are the benefits of additive manufacturing?
What are the limitations of additive manufacturing?
How is AI changing additive manufacturing?
When U.S. Air Force maintainers noticed a crack in the cooling duct of an F-15 Eagle during a 2025 inspection at Kadena Air Base in Okinawa, Japan, the prognosis was somewhat grim. Without a readily available replacement part, the Air Force estimated that the multimillion-dollar machine would be flightless for three or four months. But by turning to additive manufacturing, the Air Force was able to radically shorten the timeline from months to hours.
How is it possible to go from faulty to flightworthy so fast? Additive manufacturing (aka 3D printing) is a process that creates an object by building it up one layer at a time using materials like plastic and metal. In the case of the grounded F-15, the Air Force was able to use on-site additive manufacturing capabilities to leap over supply chain hurdles and literally print a replacement cooling duct.
Additive manufacturing isn’t new. The basic technology has been around since the 1980s. But now that additive manufacturing can produce sturdy, functional, end-use parts (as opposed to mere models), manufacturers of everything from tennis shoes to teeth straighteners are seeing the benefits and investing accordingly. In fact, the global additive manufacturing market size was estimated at more than $30 billion in 2025 and is projected to reach nearly $169 billion by 2033.
How Does Additive Manufacturing Work?
Before an object can be built by additive manufacturing, it must be designed. This is typically done using computer aided design (CAD) software. Or if you already have an object you’re wanting to reproduce, you can scan it. Either way, software will turn the design or scan into a detailed framework.
Once this data is sent to a 3D printer, the physical form begins to emerge, layer by layer. Additive manufacturing can build objects from polymers, metals, ceramics, foams, gels, and more, but the exact process can vary widely.
There are a total of seven different overarching additive manufacturing processes, as outlined in the ISO/ASTM 52900:
Vat photopolymerization
Material extrusion
Powder bed fusion (PBF)
Material jetting
Binder jetting
Direct energy deposition
Sheet lamination
Each of these seven categories is comprised of multiple methods. For example, vat photopolymerization includes stereolithography, digital light processing, and more. The best printing method depends on factors like the end product’s desired material, finish, and function.
Common 3D Printing Methods
Some of the most common plastic 3D printing methods include stereolithography, fused deposition modeling, and selective laser sintering.
Stereolithography
Stereolithography (SLA) 3D printing, also called resin 3D printing, employs vat photopolymerization technology in which a light source cures, or hardens, layers of liquid resin into a 3D object. It’s the oldest method of 3D printing and remains popular today.
According to Formlabs, “SLA parts have the highest resolution and accuracy, the clearest details, and the smoothest surface finish of all plastic 3D printing options,” making the method a “great option for highly detailed prototypes requiring tight tolerances and smooth surfaces, as well as functional parts, such as molds, patterns, and end-use parts.”
SLA-printed objects are also isotropic, meaning their strength is consistent throughout. “This results in parts with predictable mechanical performance critical for applications like jigs and fixtures, end-use parts, and functional prototyping,” Formlabs explains.
Fused Deposition Modeling
Fused deposition modeling (FDM) 3D printing, also called fused filament fabrication (FFF), may not be the first 3D printing method, but it’s become the most widely used. Printers range from entry-level (for hobbyists) to industrial-grade machines.
FDM 3D printers are part of the material extrusion category. They work by melting thermoplastic filaments and then depositing them via nozzle to build up an object, one layer after another. Formlabs recommends this method for “basic proof-of-concept models, as well as quick and low-cost prototyping of simple parts, such as parts that might typically be machined.” In contrast to SLA, FDM layers can have space between them. “This results in anisotropic parts,” Formlabs explains, “which is important to consider when you are designing parts meant to bear load or resist pulling.”
Selective Laser Sintering
Selective laser sintering (SLS) 3D printing uses PBF technology to fuse thermoplastic powder particles into 3D objects using a laser. According to Formlabs, SLS 3D printing “is trusted by engineers and manufacturers across different industries for its ability to produce strong, functional parts” at a low cost and high output. And as with SLA-printed objects, SLS 3D printing produces isotropic parts.
Because loose powder supports the object during the printing process (as opposed to dedicated support structures), Formlabs says the method can be especially useful for “complex geometries, including interior features, undercuts, thin walls, and negative features."
Post-Processing
Post-processing is the last step in the 3D printing process, in which the final touches are added to improve the object’s appearance, mechanics, or function. Raise3D divides post-processing into three categories of techniques:
Subtractive: sanding, milling, cutting, tumbling
Additive: painting, sealing, filling, foiling
Property-changing: thermal curing, chemical treatments
Post-processing can also involve removing any unnecessary support structures that were made during the printing process.
Common Applications of Additive Manufacturing
The following table breaks down some common applications of additive manufacturing by industry to provide examples of 3D printing’s widespread use.
Manufacturing |
|
Automotive |
|
Aerospace |
|
Construction | |
Dental |
|
Medical |
|
Audiology |
|
Education |
|
Entertainment |
|
Jewelry |
|
Fashion |
|
The Benefits of Additive Manufacturing
As demonstrated by fast F-15 fix in the opening, additive manufacturing can significantly shrink the supply chain — in terms of both steps (and thus parties involved), as well as time. Instead of waiting months for a factory to create, transport, and deliver the broken part, the Air Force was able to take care of everything on-site and in hours.
At a time when global supply chains are becoming increasingly volatile, additive manufacturing can simplify and shorten supply chains in ways that reduce their exposure to risk while also getting products in customers’ hands far more quickly.
If shrinking the supply chain is the 30,000-foot view, let’s zoom in on some of the opportunities and benefits 3D printing makes possible:
Reduced costs | 3D printing has lower overhead costs than traditional manufacturing.
|
Reduced waste | Because additive manufacturing builds up objects, there is very little waste created when compared to traditional (i.e., subtractive) manufacturing.
|
Customization | 3D printing enables the creation of highly custom, one-off products (like teeth aligners) at an accessible price.
|
Optimization | 3D printing can produce superior products that have improved functionality, more features, and weigh less. |
New complexity | Building by layer allows for the creation of complex geometries that are more difficult (or impossible) with traditional manufacturing.
|
On-demand production | Companies can print what they need when they need it instead of having to store inventory. This his interesting implications for companies with long-lasting products. For example, instead of keeping a supply of 20-year-old oven parts on hand, KitchenAid could simply print new parts in response to customer need.
|
Rapid prototyping | Companies can move from CAD to a 3D product in hours, significantly reducing time to market.
|
Material flexibility | 3D printers can use a wide range of materials. |
The Limitations of Additive Manufacturing
Despite all of these benefits, traditional manufacturing isn’t at risk of being fully replaced. The following limitations outlined by Raise3D highlight the important role traditional manufacturing continues to play:
Cost: Industrial-grade additive manufacturing machines aren’t cheap and can be a hurdle for smaller companies. And the need for post-processing introduces more overhead and labor costs.
Speed: 3D printing is ideal for low-volume production, but the speed at which it creates product layer by layer would have a difficult time meeting high-volume demands.
Skill: It can be difficult to find people with the right expertise to operate and maintain additive manufacturing equipment.
Quality: 3D printing isn't immune to contamination and defects.
Materials: The number of 3D printing-compatible materials has grown, but the list hasn’t overtaken that of traditional manufacturing.
Additive Manufacturing Meets AI
As with most things, AI is bringing major changes and improvements to additive manufacturing. Here’s what happens when AI and AM join forces:
Predictive maintenance: AI-powered 3D printers use IoT sensors and machine learning to continuously monitor the printer’s health and detect potential problems before they become reality. In addition to helping prevent machine downtime, AI can also help reduce maintenance costs while increasing machine longevity.
Real-time quality control: 3D printers using computer vision systems can detect defects during the printing process and are able to tell the difference between an inconsequential variation and a serious flaw. Depending on the defect, the system may be able to fix it in real-time as well.
Design optimization: AI-powered automated manufacturing software can analyze thousands of designs to choose the best one for the job, saving time and delivering a better product.
Mass customization: AI algorithms are key to scaling customization, turning individual inputs into one-of-a-kind printable designs in seconds.
Supply chain optimization: AI can produce more accurate forecasting that cuts waste and storage costs and can help streamline logistics.
Build a Better Supply Chain
Additive manufacturing isn’t the only way to improve supply chain issues. SPS Commerce offers solutions to help businesses orchestrate the data, decisions, and relationships needed to get the right product to the right place at the right time.
Whether you’re a manufacturer or you rely on one, we have supply chain solutions for you. Browse by business type below and let us know how we can help:
