Additive manufacturing (AM), also known as 3D printing, has been around for over three decades but has recently gained significant attention due to its potential to revolutionize the way products are designed, produced, and distributed.

Despite its promise, AM faces challenges, particularly in metal manufacturing. Engineers at GE Aviation acknowledge these challenges but believe they can be overcome. The company aims to make plane engines 1,000 pounds lighter using AM.

AM excels in meeting the "form" requirement of a part, which refers to its physical characteristics. However, it struggles with the "fit" and "function" aspects. Fit refers to how well the part fits with other components, while function refers to its performance and durability. Achieving tight dimensional control requires refinement of the additive cycle and secondary processes like machining.

General Atomics, the maker of the Predator and SkyGuardian remote aircraft, is leveraging AM to produce components more quickly and cost-effectively. This approach hints at the potential of AM in aircraft production and design.

AM offers several advantages, including reduced weight, increased complexity, reduced material waste, customization, and supply chain optimization. It enables the creation of lighter parts, leading to significant weight reduction in aircraft. AM also allows for the production of complex geometries and designs, enabling the creation of optimized and asymmetric objects.

AM is being explored in various industries, including aerospace, medical, automotive, and energy. In the aerospace industry, companies like GE Aviation and General Atomics are leveraging AM for aircraft components. In the medical field, AM is being used to produce customized implants, prosthetics, and medical devices. In the automotive sector, AM enables the production of complex engine components, reducing weight and increasing efficiency. In the energy sector, AM is being explored for the production of critical components in the clean energy sector.

As the industry continues to evolve, we can expect to see widespread adoption of AM across various sectors. Additive manufacturing is poised to transform the production industry, enabling the creation of complex products with reduced weight, increased efficiency, and customized attributes.