Podcast: From prototypes to production — The practical advantage of 3D printing

Key takeaways

Additive manufacturing (AM) enables rapid prototyping, reducing lead times and accelerating product development.
Hybrid workflows using AM and CNC boost precision, efficiency, and material utilization in production.
AM allows cost-effective low-volume production, ideal for complex parts in aerospace, automotive, and medical sectors.
Integrating AM with digital tools supports agile, data-driven manufacturing aligned with Industry 4.0 goals.

In this episode of Great Question: A Manufacturing Podcast, Robert Brooks, editor in chief of American Machinist and Foundry Management and Technology, reviews the additive manufacturing (AM) market. Drawing from Patrick Wirt’s article "Bridging the Gap Between Prototypes and Production," the discussion highlights how AM technologies enhance speed, flexibility, and cost-efficiency in prototyping and low-volume production. The conversation also touches on the integration of AM within hybrid manufacturing models and digitalized production environments. Together, they offer a clear-eyed perspective on how additive manufacturing complements — rather than replaces — traditional methods in today’s manufacturing landscape.

Below is an edited excerpt from the podcast:

Recently there has emerged some concern or confusion about whether U.S. import tariffs on steel and aluminum will affect prototype products made in those materials, which is worth a separate discussion, but Patrick Wirt's article preceded that for us. His focus is on prototyping, however, which is why I bring it to your attention. I view the article as a helpful return to baseline for additive manufacturing after several years of organizational turmoil among the top suppliers of AM systems. That turmoil had virtually nothing to do with AM processes or technology developments, and it had almost everything to do with the finances of that industrial sector.

Now here I'm editorializing to add that the organization and finances of the additive manufacturing and 3D printing sector had been distorted because investors were impatient with the rate of adoption of those technologies among manufacturers worldwide. Those backers wanted additive manufacturing and 3D printing to be much more disruptive to manufacturing than it has been. (There are numerous reports that americanmachinist.com and foundrymag.com describing all those developments since 2022.) But that upheaval has stabilized since the start of this year, I'm glad to report.

The latest issue of the Wohlers Report, which is the most widely recognized source of additive manufacturing market intelligence, offers that in 2024 the global AM industry reached $21.9 billion in market value, up 9.1% from 2023. The new total included $4.44 billion from material sales, $6 billion from machine sales and related services, $10.1 billion from printing services, and $1.4 billion in sales from software. Most of the growth for the a ministry last year was centered in Asia, especially in China. Wohlers reports that for Europe there was just moderate growth in the additive manufacturing sector but in North America there was negative growth, so the additive manufacturing sector needs more European and North American adopters of their technologies.

This is the reason that Patrick Wirt’s article at americanmachinist.com is relevant, particularly in the context of import tariffs, which many machine shops and other manufacturers may anticipate will draw more inquiries for their services. This article makes the case a current one, but referencing factors that have been well established that adopting additive manufacturing and 3D printing has practical advantages that support and enhance established manufacturing operations.

I quote the author:

“Speed is one of the most significant advantages of additive manufacturing in the prototyping phase between product design and production planning. In conventional workflows, creating a single metal prototype may require days or even weeks, especially when toolpaths, workholding, and custom fixtures are involved. In contrast, AM allows same-day turnaround for functional prototypes, particularly when using polymer-based systems or metal binder jetting. Faster prototypes allow engineers to evaluate and revise designs early and often. This rapid iteration has several practical effects:

Accelerated design validation: Get real-world feedback quickly without waiting on lengthy machine set-ups.
Reduced bottlenecks: Design and development timelines can shrink significantly.
Cost savings: Errors are caught earlier, reducing the risk of expensive late-stage redesigns.

"Machine shops using AM in tandem with CAD/CAM workflows can produce test parts overnight and run dimensional or functional checks first thing the next morning. This not only streamlines development cycles, but also:

Increases shop flexibility for last-minute client changes.
Improves throughput by minimizing downtime between design and machining.
Builds client trust through faster response times and visible progress.

"Another important benefit of additive manufacturing is cost-efficiency at low volumes. Standard manufacturing often relies on economies of scale — producing a few parts can be disproportionately expensive due to set-up and tooling costs. Additive manufacturing sidesteps those costs by removing the need for custom tooling.

"Now, machine shops can offer small-batch or custom parts at competitive prices, filling a previously underserved niche. This capability is especially useful in industries such as aerospace, automotive, and medical devices, where low-volume parts may still require complex geometries and strict tolerances.”

About the Podcast
Great Question: A Manufacturing Podcast offers news and information for the people who make, store and move things and those who manage and maintain the facilities where that work gets done. Manufacturers from chemical producers to automakers to machine shops can listen for critical insights into the technologies, economic conditions and best practices that can influence how to best run facilities to reach operational excellence.