How Additive Manufacturing Minimizes Risk in Modern Production Lines

Production lines are intricate systems, and maintaining flawless operation demands expertise and foresight. Hundreds of supply‑chain elements—from heavy machinery and wear parts to tiny jigs, brackets, and grippers—can each become a single point of failure. In this article, we explore how additive manufacturing (AM) can eliminate those vulnerabilities and streamline your manufacturing workflow.

CNH Industrial, one of the world’s leading capital‑goods manufacturers, began using AM for prototyping a decade ago. Today, it leverages the technology to eliminate risk at every stage of production, turning AM from a design tool into a strategic risk‑management asset.

When COVID‑19 Disrupted Supply Chains

Manufacturers face a spectrum of risks—from market shifts and regulatory changes to staff illness and unscheduled downtime. The pandemic exposed how fragile these systems can be, as global transport shutdowns cut off access to raw materials and critical components.

CNH Industrial’s supply chain was no exception. A key component from China was delayed, threatening to halt production and jeopardize customer commitments.

Without AM, CNH Industrial would have faced significant delays during the pandemic.

The alternative—shutting down the line or waiting for parts—would have cost both time and revenue. By turning to 3D printing, the company produced a replacement part in just one week, at €15 per unit versus the usual €2, and with a total AM cost of €806. Compared to a potential loss of €189,000, the investment proved decisive.

Mitigating Reputational Risk

A production pause could erode customer trust and damage the brand. Delivering the 3D‑printed component enabled CNH Industrial to keep its production schedule intact, preserving relationships and preventing downstream financial impacts.

The printed part was not only functional but also cost‑effective in the long run, demonstrating that AM can offset higher per‑unit prices with reduced lead times and avoided loss.

Although the 3D‑printed replacement is not as affordable, it ultimately saves substantial costs.

Staying Safe: Health & Safety Risks

AM has been part of CNH Industrial’s strategy for years, with 50% of its facilities now incorporating the technology to support manufacturing operations. During the pandemic, the company partnered with Materialise Mindware to produce hands‑free door‑opening devices, allowing single‑person operation of tasks that previously required multiple staff.

These solutions also extended to the community: the company printed PPE for local hospitals and schools, reinforcing its commitment to public health.

The pandemic highlighted AM’s broader potential to mitigate supply‑chain fragility, health risks, and reputational concerns, solidifying its role as a cornerstone of resilient manufacturing.

3D‑printed hands‑free door openers provided rapid, safe solutions during the pandemic.

Why Preparing for Plan B Is the Ideal Plan A

Assuming a return to pre‑pandemic normalcy is risky; recent disruptions—such as the Suez Canal blockage, freight staff shortages, and CO₂ supply constraints—have shown that supply chains remain volatile.

AM offers a proactive approach: by reducing reliance on external suppliers, it shortens lead times, lowers downtime, and gives manufacturers greater control over costs and inventory.

Beyond supply‑chain resilience, AM also enhances safety. Custom production‑line tools, ergonomic jigs, and high‑performance brackets lessen human error and equipment failure, protecting workers and maintaining throughput.

In many cases, adopting AM to mitigate risk unlocks innovation, operational efficiencies, and cost savings—all while building a safety net that protects production and the business.