Jabil’s Rush LaSelle Explains How Additive Manufacturing is Revolutionizing Global Production

Jabil, a $22 billion manufacturing powerhouse, operates over 100 facilities across 29 countries and employs 190,000 people worldwide. From industrial design to end‑to‑end supply chain logistics, the company delivers comprehensive manufacturing solutions to Fortune 500 clients.

With a longstanding reputation in 3D printing, Jabil recently launched Jabil Engineered Materials, an initiative that expands the polymer catalog available for additive manufacturing and accelerates adoption across industries.

AMFG interviewed Rush LaSelle, Jabil’s Senior Director of Digital Manufacturing, to explore the firm’s strategic vision for additive manufacturing. LaSelle brings 25 years of experience in advanced manufacturing—particularly robotics and automation—and now drives Jabil’s growth in the additive space.

What does your role at Jabil entail?

I joined Jabil five years ago, focusing on digital manufacturing—a term that covers both automation and additive processes. Our goal is to infuse the agility of software development into physical production, creating factories that are responsive, flexible, and ready for digital commerce.

My current priority is building business models and operational frameworks that enable additive technology at scale. In Jabil’s view, additive manufacturing is the key to redefining how we distribute production footprints, turning massive factories into modular, on‑site kiosks that can deliver products faster and more cost‑effectively.

Which areas of additive manufacturing are you concentrating on?

We target intersections between traditional high‑volume processes—such as injection molding and CNC machining—and additive solutions. Our customers demand shorter product lifecycles; for example, the mobile phone industry now expects a one‑year cycle instead of three. To remain competitive, we identify applications where 3D printing delivers economic and performance advantages.

On the design side, we explore generative design in aerospace, producing lighter, stronger components that reduce both weight and cost. Our evaluation spans both the factory floor and the digital front end, ensuring end‑to‑end integration.

How is additive manufacturing reshaping supply chains?

Additive manufacturing empowers companies to produce small batches—10 units—where they previously required millions, dramatically reducing inventory and lead times.

We have proven that a single digital file can be deployed across facilities in Singapore, San Jose, and Michigan, allowing immediate local production. This capability shortens supply‑chain complexity and grants customers unprecedented flexibility.

What additional opportunities does additive manufacturing present?

Part consolidation is a major benefit; redesigning multiple components into one reduces assembly costs, storage needs, and streamlines production.

In aerospace and high‑performance automotive, additive manufacturing enables weight reduction and aerodynamic improvements, unlocking designs that were impossible with conventional methods.

How does Jabil approach standardisation?

Standardisation is multilayered. We maintain ISO 9001 certification as the baseline for repeatable, rigorous manufacturing. For aerospace, we meet AS9100, and for medical implants we comply with industry‑specific regulations.

Our process—called MPM (Materials, Processes, Machines)—qualifies each component by ensuring material, printer, and process meet the necessary standards, creating a solid foundation for high‑quality additive parts.

How does standardisation differ for additive versus injection moulding?

Unlike the static tooling of injection moulding, additive manufacturing introduces variability across print runs. We capture extensive data to meet certification requirements, ensuring every part meets the same stringent standards.

What measures does Jabil take to secure data?

We use secure, ITAR‑compliant servers to protect proprietary CAD files and digital processes. This security extends to the manufacturing environment, ensuring that intellectual property remains protected throughout the production cycle.

What is the vision behind Jabil Engineered Materials?

High material costs have historically limited additive adoption. By sourcing polymers at lower prices and developing new grades in-house, we fill the gap between OEM volumes and the current additive market, providing customers with tailored materials that meet their specific needs.

We partner with established chemical companies to validate new materials, positioning ourselves as an agile competitor that can deliver both performance and cost efficiency.

Is Jabil exploring metal materials?

Yes, we are actively researching metal options. Our client base, which includes many Fortune 350 companies, is increasingly requesting metal parts. While polymer development is further along, metal capabilities are a priority.

Will additive manufacturing reach high‑volume production?

High‑volume additive use is already evident in sectors like dental aligners. As technology matures, we anticipate broader adoption across automotive and aerospace, complementing existing CNC and injection moulding operations rather than replacing them.

Can you share a recent success story?

Our partnership with HP on the Multi‑Jet Fusion (MJF) platform showcases our capabilities. We qualified 150+ polymer parts for MJF printers, established full quality systems, and successfully transferred the production process to facilities in Singapore, matching the performance of our U.S. operations.

Additional projects include metal implant printing and spare‑part production for off‑road vehicles, illustrating the expanding scope of additive manufacturing at Jabil.

What advice do you have for companies new to additive manufacturing?

Collaboration is key. Engage with suppliers, competitors, and academia to build an ecosystem that supports design, qualification, and scaling of additive solutions.

Reading “The Pan‑Industrial Revolution” by Richard D’Aveni offers valuable insight into how new manufacturing giants are reshaping the industry.

What trends will shape the next five years?

Beyond cost, the biggest barrier is adopting design, qualification, and utilisation strategies. A cultural shift is required for large enterprises, while younger talent will drive digital transformation and democratise manufacturing.

What challenges must be overcome to accelerate adoption?

Regulators like the FDA and FAA must modernise certification processes to match digital production speeds. Additionally, intellectual‑property frameworks need to adapt to the reality that digital files can be replicated instantly.

Is Industry 4.0 already a reality?

Absolutely. The integration of cloud‑connected physical assets, combined with additive manufacturing, is revolutionising spare‑part availability for high‑value equipment such as aircraft, military hardware, and mining machinery.

What are Jabil’s next steps in additive manufacturing?

We plan to expand digital manufacturing across our 130+ facilities, enhancing our ability to deliver on‑demand production worldwide. As the cost curve narrows, more applications will transition to additive processes, further expanding our service portfolio.

Final thoughts

Managing the digital thread—from design file to quality systems—is complex but essential. We are working towards comprehensive solutions that address cost, design, and production challenges for additive manufacturing.

To learn more about Jabil, visit: https://www.jabil.com/additive

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