How 3D Printing Fuels Industry 4.0

How 3D Printing Fuels Industry 4.0

Editor's note: This article is part of AspenCore’s special report “Enabling the Factory of 2030.”

Imagine printing an entire, functional smartphone on a desktop—while still a distant vision, additive manufacturing (AM) is already reshaping how electronic components, from connectors to printed‑circuit boards, are produced.

According to a recent Hubs report, rapid advances in printers, materials and software have moved 3DP from prototyping to reliable end‑use production. “We’re at an inflection point where end‑use parts are now common,” says Sam Manning, spokesperson for the $101 million Markforged.

Industrial Impact

3DP eliminates the need for overseas partners, reduces IP risks, and enables on‑site production in the exact quantities required. This “just‑in‑time on steroids” approach cuts minimum order quantities, shipping lead times, and inventory costs.

Flex, the $29.72 billion EMS provider, has identified 3DP as a pillar of its Industry 4.0 strategy. Rapid digital prototypes bridge the gap between design and manufacturing teams, creating a live digital repository that updates instantly with every design change.

Process automation—slicer optimization, smart part orientation, batch layout and post‑processing—drives print speed, quality and consistency. Slicing converts a 3D model into the machine‑readable instructions that the printer follows.

“Factories no longer need to store parts for years,” Manning explains. “If you need a part, you can print one on demand.”

What’s New in 3DP

The 3DP ecosystem now includes large‑format metal AM, such as SLM Solutions’ 1.5‑meter Z‑axis laser‑powder‑bed‑fusion system for the U.S. Air Force, and Caracol’s near‑net‑shape metal wire‑arc system that uses robotic welding arms for large structures and repairs.

The largest printed tool to date is a trim tool used by Boeing to hold the 777X wing skin during machining. 3DP materials span engineering thermoplastics, resins, composites, polymer powders and metal powders, with recent breakthroughs in non‑planar printing that eliminate supports for overhangs.

Manning notes, “We don’t just make printers; we develop materials and software. An integrated, AI‑driven ecosystem accelerates adoption.”

Use Cases

3DP excels in prototyping, tooling and mass customization. Rapid prototypes allow designers to validate form, fit and function before full‑scale production. Tooling—jigs, fixtures and assembly aids—can be printed on demand, reducing machine downtime and boosting agility. Toyota, for example, cites faster lead times and design freedom as key benefits of AM tooling.

Low‑volume manufacturing becomes economically viable. Companies can produce limited‑edition items or spare parts without large inventories. HP’s 3D printers are used by Toyota to print replacement parts on demand.

Mass customization is possible when CAD files are tailored to individual customers. Formify uses 3DP to produce ergonomic mice based on hand scans.

Serial production is also emerging: Protolabs operates a fleet of 150 3D printers, delivering up to 1 million parts annually, a feat enabled by fully automated, lights‑out workflows.

Sustainability

Manufacturers face pressure to cut costs while reducing environmental impact. 3DP produces less material waste than subtractive methods like CNC machining and can recycle unused powder. It also consumes less power, with robots like Athena Manufacturing’s lights‑out system continuously preparing and printing parts.

AI‑powered design tools minimize failed prints and optimize CAD models, further reducing waste. Localized production eliminates complex logistics, lowering carbon footprints. Lightweighting components by 20 % can boost fuel efficiency by 10 % in aircraft, according to Hubs.

Long‑life assets such as aircraft and cars benefit from on‑demand spare parts, extending their operational life.

Market Outlook

In 2022, the 3DP market—including systems, software, materials and services—reached $17 billion, growing at 13 % annually. Hubs projects a 17 % CAGR, reaching $19.9 billion in 2023.

“3DP is a powerful tool for engineers,” Manning says. “It won’t replace traditional manufacturing, but it’s becoming a standard part of the design toolkit.”

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