Applications of 3D Printing in Manufacturing

Last updated: 5.3.2025

Whether you're an operations manager looking to streamline production workflows or an engineer tasked with solving complex design challenges, 3D printing has become a transformative tool in modern manufacturing.

This article will explore how 3D printing is being applied across the manufacturing industry, from custom tooling and rapid prototyping to on-demand spare parts production, highlighting real-world examples and key benefits for professionals striving to maintain a competitive edge in their operations.

Introduction to 3D printing in manufacturing

3D printing, also known as additive manufacturing, has revolutionized industrial applications across numerous sectors. This transformative technology allows for the creation of three-dimensional objects by depositing materials layer by layer based on digital designs.

As we explore the impact of 3D printing in manufacturing, it's important to understand how this innovation is reshaping traditional production processes and opening up new possibilities for businesses.

The adoption of 3D printing in industrial settings has grown exponentially in recent years, driven by advancements in materials, hardware, and software. This technology offers several key advantages over conventional manufacturing methods:

• Design flexibility: Complex geometries that were previously impossible or prohibitively expensive to produce can now be easily created.
• Rapid prototyping: Companies can quickly iterate designs and test concepts, significantly reducing product development cycles.
• Customization: 3D printing enables cost-effective production of personalized or low-volume products.
• Reduced waste: As an additive process, 3D printing typically uses only the material necessary for the final product.
• Supply chain simplification: On-demand production can reduce inventory costs and lead times.

These benefits are driving the integration of 3D printing across various industries, from aerospace and automotive to healthcare and consumer goods. As the technology continues to mature, we're seeing a shift from primarily prototyping applications to end-use part production and even full-scale manufacturing operations.

In the following sections, we'll delve deeper into specific industrial applications of 3D printing, exploring how different sectors are leveraging this technology to innovate, improve efficiency, and gain competitive advantages in the global marketplace. For a comprehensive overview of how 3D printing applications have evolved over time, you can refer to our article on the evolution of 3D printing applications.

Key advantages of 3D printing in industrial applications

Enhanced design freedom and complexity

One of the most significant advantages of 3D printing in manufacturing is the unprecedented design freedom it offers. Unlike traditional manufacturing methods, which often have limitations due to tooling or machining constraints, 3D printing allows for the creation of highly complex geometries. This capability enables engineers to design parts with optimized structures, such as lattices or honeycomb patterns, that can reduce weight while maintaining strength. In aerospace applications, for example, this translates to lighter components that can improve fuel efficiency without compromising safety.

Accelerated product development cycles

Rapid prototyping is a key benefit of 3D printing. However, the impact on product development goes beyond just faster prototypes. The ability to quickly iterate designs allows for more thorough testing and refinement before committing to full-scale production. This agility can significantly reduce time-to-market for new products and help companies stay ahead of competitors. Moreover, the reduced cost of prototyping encourages innovation by lowering the barriers to testing new ideas.

Mass customization and on-demand manufacturing

3D printing is revolutionizing the concept of mass production by enabling mass customization. Unlike traditional manufacturing methods that rely on economies of scale, 3D printing allows for cost-effective production of customized or low-volume products. This capability is particularly valuable in industries like healthcare, where patient-specific implants or prosthetics can be produced, or in consumer goods, where personalized products are increasingly in demand.

Material efficiency and sustainability

The additive nature of 3D printing inherently reduces material waste compared to subtractive manufacturing methods. In industries where expensive materials are used, such as aerospace or medical device manufacturing, this efficiency can lead to significant cost savings. Additionally, the ability to produce parts on-demand reduces the need for large inventories, further contributing to resource efficiency and sustainability in manufacturing operations.

Supply chain optimization

3D printing has the potential to dramatically simplify supply chains. By enabling on-site production of parts and components, companies can reduce their reliance on complex logistics networks. This localized production model can lead to shorter lead times, lower transportation costs, and increased resilience to supply chain disruptions. For industries with strict regulatory requirements or intellectual property concerns, in-house production also offers greater control over the manufacturing process.

Tooling and fixture production

Beyond end-use parts, 3D printing is proving invaluable for producing manufacturing aids such as jigs, fixtures, and tooling. These custom tools can be produced quickly and cost-effectively, allowing manufacturers to optimize their production processes without the long lead times and high costs associated with traditional tooling methods. This application of 3D printing can lead to significant improvements in overall manufacturing efficiency and flexibility. To learn more about the top applications of 3D printing in manufacturing, including tooling and fixtures, check out our guide on 5 top applications every manufacturer should be 3D printing.

Industries leveraging 3D printing technology

Aerospace and defense

The aerospace industry was an early adopter of 3D printing. Companies are now using additive manufacturing to produce complex, lightweight components that significantly reduce fuel consumption and emissions. For example, some manufacturers have successfully 3D printed fuel nozzles for jet engines, consolidating multiple parts into a single unit and achieving substantial weight reduction.

Check out our whitepaper on 3D printing in Aerospace

Automotive

Automotive manufacturers are embracing 3D printing for both prototyping and end-use parts. Companies are using the technology to create custom tools and fixtures, reducing production line downtime. Additionally, luxury automakers are exploring 3D-printed customization options for consumers, allowing for personalized interior components and accessories.

Healthcare and medical devices

The healthcare industry has seen remarkable advancements through 3D printing. Beyond prosthetics and implants, companies are now producing patient-specific surgical guides, dental aligners, and even bioprinted tissues for drug testing. The ability to create anatomically accurate models from CT or MRI scans is revolutionizing surgical planning and medical education.

Consumer goods and electronics

Consumer electronics manufacturers are utilizing 3D printing for rapid prototyping and small-batch production. Companies are exploring ways to integrate 3D-printed components into their products, potentially enabling more modular and repairable designs. In the fashion industry, brands are using 3D printing to create custom midsoles for sneakers, offering unprecedented levels of personalization.

Industrial machinery and tooling

3D printing is transforming the production of industrial tools and fixtures. Machine shops and manufacturing facilities are increasingly bringing 3D printing in-house to create custom jigs, gauges, and end-of-arm tooling for robots. This on-demand production capability is reducing downtime and improving overall operational efficiency.

Construction and architecture

While still in its early stages, 3D printing is making inroads in the construction industry. Companies are exploring large-scale 3D printing of building components and even entire structures. This technology has the potential to reduce construction waste, speed up building processes, and enable more complex architectural designs.

For a more detailed exploration of key 3D printing applications across various industries, you can refer to our article on 5 key 3D printing applications.

Ultimaker case study: Custom jigs, fixtures, and tooling

Across the entire manufacturing landscape, jigs, fixtures, and tooling play a pivotal role in ensuring product quality, assembly accuracy, and production speed. Traditionally, creating these components required time-intensive machining and significant costs, especially for customized solutions. 3D printing allows for a vastly more rapid, efficient, and cost-effective way of producing these parts.

Several of our clients such as ERIKS, Volkswagen Autoeuropa, Zeiss, and IME Automation have already implemented 3D printing technology to create various jigs and fixtures to streamline and improve their manufacturing capabilities.

Here’s a few examples:

ERIKS - Motor and drill alignment jigs

The implementation of the motor jig, for example, allowed for an easier assembly of the components minimizing the chance of assembly errors while also making the process 3 times faster (assembly time previously took around 3 minutes which was cut down to one).

According to ERIKS:

For us the primary benefit of 3D printing is speed. How quickly can we get something? And that is where 3D printers are the fastest option you can get. I can turn on a print job at 2 pm one day, and the next morning I come into the office and now I have the tools ready. So that is the main factor why we choose 3D printing over conventional methods, whenever we can. Cost is a side benefit for us.

Volkswagen Autoeuropa - Manufacturing tools

Volkswagen Autoeuropa has switched to 3D printing in order to produce the vast majority of tools used in their manufacturing line and has seen tool development time reduced by up to 95% and costs by 91% (saving an estimated $375.000 per year).

Zeiss - Adapter plate and label placement gauge

For Carl Zeiss Optical Components, precision is paramount when manufacturing microscopes, multi-sensoric machines and optical sensors for industrial measurement and quality assurance purposes.

Their implementation of UltiMaker’s 3D printing technology not only enabled them to create bespoke adapter plates for each of their microscopes in serial production streamlining the process but also made supporting those parts for their clients a lot easier, as spares could be printed on demand and sent to a client’s location. Previously they had to produce several parts, mount them together, and adjust them which was a more costly and time-consuming process.

Taking label placement gauges as another example, previously made out of POM (polyoxymethylene), the sharp corners would lead to breakage if dropped. Adding in the fact that POM is traditionally made by injection molding or extrusion, itself a costly process, would often require CNC machining to create the desired part.

In contrast, the new 3D printed gauges allowed products to slide in and out of the tool effortlessly while also being less fragile, more wear-resistant and could be printed to achieve tight tolerances, all while having a print time of just 3 hours at €2.20 per part.

IME Automation - Box folding jig

With a focus on precision, efficiency, and innovation in the field of building custom automated robotics for manufacturers IME Automation turned to 3D printing to test and create a wide range of applications to be more agile and flexible in their manufacturing process.

One of the most notable examples is the one that started them on the path of using 3D printing technology, their patented box folding jig.

Used to erect or fold cartons their customers previously had to either buy an off-the-shelf carton erector or a full-fledged cartoner which were big, cost prohibitive, and offered no flexibility to changes due to the long times required to adapt them.

The 3D printed folding box jig IME Automation developed was a game changer as they could iterate a wide variety of shapes and sizes with less than 2-minute part changeover times.

Rapid Prototyping and End-Use Parts Production

As previously hinted, 3D printing allows for direct fabrication of prototypes from CAD models, bypassing the need for complex tooling or molds. This capability significantly shortens development cycles and enables designers to test, modify, and validate designs with a high degree of speed and flexibility.

Unlike traditional subtractive manufacturing processes, additive manufacturing allows for the creation of designs with complex geometry, overhangs, and organic shapes at a reduced cost and complexity. This innate feature allows 3D printing to bridge the gap between prototyping and large-scale production, allowing companies to produce end-use parts without the need for expensive and time-consuming tooling. Our clients Sylatech and Snow Business offer some great examples in this regard:

Sylatech - Yacht propeller prototype

An investment casting firm, Sylatech was previously unable to test design functionality without using tooling investment casting, a time-consuming and costly process, typically taking three to four weeks with customers paying £2,000-4,000 per tool. Add in the fact that approximately 30% of tools require some sort of alteration, which can cost up to £900, it’s easy to see why they needed a solution to reduce lead times and costs.

Using UltiMaker’s 3D printing technology they were able to reduce the development time of a yacht propeller from four weeks to just three days and brought down the total cost from £17,100 to £15,660 (including casting tooling costs).

Taking into account that with 3D printing only 5% of tools needed alteration, Sylatech’s ROI for an UltiMaker 3D printer was less than 3 months.

Snow Business - Snow machine nozzle

With over 35 years of experience in the artificial snow industry for film and TV effects production, Snow Business has leveraged 3D printing to prototype, functionally test and create final parts for their machines. For example, the nozzles on their snow machines could be 3D printed in-house within seven hours at £2.50 each, negating the need for an SLS service which took up seven days with a minimum £125 per order. They estimate that their UltiMaker printer paid for itself within just two weeks.

On-Demand Spare Parts and Maintenance

In traditional manufacturing, maintaining a stock of spare parts for machinery or production lines often requires significant investment in inventory and storage space. Long lead times for replacement parts can result in costly production delays.

3D printing eliminates these challenges by enabling the on-demand production of spare parts directly on location, aside from the greater flexibility and cost efficiency in maintenance operations, manufacturers can leverage 3D printing to also extend the lifespan of existing machinery far beyond the OEM’s support cycle which is an often underreported benefit that directly translates to lower production costs and higher production uptimes.

Some of our clients, such as Trivium and Heineken, have integrated UltiMaker’s ecosystem precisely for this reason:

Trivium - Conveyor infeed worm and silicone seals & gaskets

In Trivium’s case, the original packaging machine had worn out and was no longer available from the supplier and manufacturing it via traditional methods such as CNC milling was cost prohibitive and time consuming. 3D printing the part in a low cost material such as ABS allowed them to validate the design and switching to carbon reinforced nylon netted them a durable replacement part that allowed them to keep their production rolling.

Similarly, the molds needed for silicone seals and gaskets needed for different machines were either too expensive or, as was the case for the infeed wheel, no longer available.

Using ABS printed with a 60 micron layer height, Trivium was able to cleare smooth and accurate molds for silicone which could be reused and reprinted on demand, saving time and money.

Heineken - Stopper tool

After the implementation of 3D printing technology in their Seville plant, Heineken was able to improve their manufacturing process in terms of output, uptime, and safety. We recommend reading further on how Heinken ensured production continuity with 3D printing for a more comprehensive list of applications, but for this example, we want to showcase their stopper tool.

As a custom tool used to loosen or tighten the columns for the guiding wheels that apply bottle labels, the 3D printed version of the tool was 70% cheaper to produce than the previously CNC machined one and done within a single day instead of three.

IMES3D - The Power of Partnership

For a holistic view of how UltiMaker’s complete ecosystem can help manufacturers and businesses integrate 3D printing technologies into their workflows effectively, we turn to IMES3D, one of our clients and partners, as an example of leading the charge in the transformative nature of 3D printing technology.

Offering professional support and a full suite of comprehensive services, IMES3D specializes in designing and implementing 3D printing solutions tailored to their customers specific operational needs. From printing parts and support in selecting the right materials they also offer consulting services for companies looking to adopt additive manufacturing and integrate it into existing workflows.

In order to support their clientele spanning a wide range of industries, including automotive, food and beverage, military and medical sectors, they rely on UltiMaker’s unique ecosystem to ensure that their 60+ printer fleet is utilized as efficiently as possible.

Elaborating on UltiMaker’s ecosystem this is comprised of 3 main parts:

Hardware:

• S Series
• Method Series
• Factor Series

Software:

• Cura
• Digital Factory

Materials & Partners:

• UltiMaker materials
• 3rd party partner materials

Along with UltiMaker Cura which is a fast and easy-to-use slicer, Digital Factory is used to easily manage all of the printers in the network, and ensure that projects get sent to the right printer and queues are monitored. Additionally, some customers have also started using Digital Factory which enables IMES3D to leverage the software as a key support tool being able to remotely send and queue prints from their facility.

Their expertise spans technology, material science, and production optimization, which is why we highly recommend watching our recent webinar with IMES3D to get a full picture of how they are advancing industrial 3D printing together with UltiMaker’s ecosystem.

But for those interested in a couple of short granular examples of applications we’d like to showcase two that were made possible with the addition of the new UltiMaker Factor 4 printer:

Flexible bumpers for PDA’s

Considering that most PDA manufacturers do not make any protective covers for their devices, resulting in drastically reduced lifespans due to accidental drops or mishandles, IMES3D designed and printed a wide variety of custom bumpers made out of soft TPU filament.

The ability to print in a variety of colors also allowed IMES3D to color code the bumpers according to their customer’s specifications.

Mold for part injection

The ability to print in UltiMaker’s new PPS CF carbon reinforced filament, opened up the possibility of replacing metal parts with the new composite material. With extreme durability and high-temperature resistance (HDT B of over 230°C printing), IMES3D was able to create a mold connector used for injecting parts for water and air pipes.

Traditional manufacturing vs 3D printing: A comparative analysis

Design flexibility and complexity

3D printing offers unprecedented design freedom. Traditional manufacturing methods like injection molding or CNC machining often have geometric limitations due to tooling constraints. In contrast, 3D printing can produce complex internal structures, organic shapes, and intricate lattices without additional cost or complexity. This capability not only enables innovative designs but also allows for part consolidation, reducing assembly time and improving reliability.

Customization and low-volume production

While traditional manufacturing excels in high-volume production, it struggles with customization and low-volume runs due to the high costs of tooling and setup. 3D printing shines in these areas, enabling cost-effective mass customization and on-demand production. This flexibility is particularly valuable in industries where personalization is key or where demand is unpredictable.

Lead times and iteration speed

Traditional manufacturing often involves lengthy lead times for tooling production and setup. In contrast, 3D printingcan go from digital design to physical part in a matter of hours. This rapid turnaround allows for faster iteration cycles and more agile product development processes. However, for high-volume production, traditional methods still often have the advantage in terms of speed.

Material options and properties

While traditional manufacturing has a wide range of material options with well-understood properties, 3D printingmaterials are continually evolving. New alloys and composites are being developed specifically for additive processes. However, traditional manufacturing still holds an edge in certain high-performance applications where material properties are critical and well-established.

Cost structures

Traditional manufacturing typically involves high upfront costs for tooling but low per-unit costs at high volumes. 3D printing, on the other hand, has minimal upfront costs but higher per-unit costs that remain relatively constant regardless of volume. This makes 3D printing more economical for low to medium production runs, as we saw with on-demand spare parts production.

Waste and sustainability

3D printing is generally a more sustainable process, producing less waste as it only uses the material needed for the part. Traditional subtractive manufacturing methods often generate significant waste. However, the recyclability of some 3D printing materials is still a challenge, and the energy intensity of the process can be high for certain technologies.

Quality and consistency

Traditional manufacturing methods, refined over decades, often provide high levels of consistency and well-understood quality control processes. While 3D printing quality has improved significantly, as evidenced by its use in critical aerospace components, ensuring consistent quality across large production runs remains a challenge for some additive technologies.

Supply chain implications

3D printing has the potential to significantly simplify supply chains through on-demand, localized production. Traditional manufacturing often relies on complex global supply chains, which can be vulnerable to disruptions. However, the established nature of these traditional supply chains also provides certain efficiencies and economies of scale that are still being developed for additive manufacturing.

Future trends and innovations in 3D printing for manufacturing

Advanced materials

Researchers are developing new high-performance materials specifically designed for 3D printing. These include advanced metal alloys, ceramics, and composite materials that offer improved strength, heat resistance, and functionality. For example, the development of printable superalloys could further expand aerospace applications, while biocompatible materials are advancing medical implant possibilities.

Ultimaker: Materials Enabling Versatility in Manufacturing

UltiMaker’s ecosystem of advanced printing solutions provides manufacturers with the flexibility to choose from a wide range of materials tailored to specific applications. From durable industrial plastics to flexible polymers, these materials enable the production of functional parts that can withstand the rigors of industrial environments even replacing traditional materials such as aluminum or steel in certain applications without compromising on part reliability or function.

As a reference starting point here are 3 of the materials used in the above examples:

UltiMaker Tough PLA:

• Applications: Strong and impact-resistant parts such as jigs, fixtures, and prototypes.
• Use case: Heineken uses Tough PLA to print durable production line components, including bottle guides and tool organizers, ensuring longevity while maintaining cost-effectiveness​

UltiMaker Nylon CF

• Applications: High-strength, abrasion-resistant parts like gears, bushings, and conveyor belts.
• Use case: Trivium Packaging leverages carbon reinforced nylon for parts like conveyor infeed worms, which must endure high wear and tear in a manufacturing environment

UltiMaker ABS

• Applications: Durable parts requiring smooth surface finishes, such as molds and protective covers.
• Use case: Zeiss’s adapter plates and label placement gauges are both made from ABS.

We recognize that material selection is one of the cornerstones of successful 3D printing applications in manufacturing and with a selection of over 200+ materials on the Marketplace, we’ve recently expanded the possibilities available on a single print with our dual-extrusion Factor 4 printer:

• Support Materials: Soluble supports like PVA allow for complex geometries with overhangs or internal structures that would otherwise be impossible to produce through traditional methods.
• Composite Structures: Pairing flexible materials like TPU with rigid materials like nylon creates parts with hybrid properties, such as flexible joints or shock-absorbing elements.

Artificial Intelligence and Machine Learning integration

To address consistency and quality control challenges, AI and machine learning algorithms are being integrated into 3D printing processes. These technologies can optimize print parameters in real-time, predict and correct for potential defects, and even generate optimized designs based on specified performance criteria. This integration promises to improve part quality, reduce waste, and accelerate the design process.

High-speed continuous printing

Innovations in printer design are tackling the speed limitations of current technologies. Continuous liquid interface production (CLIP) and other emerging techniques promise to dramatically increase print speeds, potentially making 3D printing competitive with traditional methods for higher volume production runs.

Large-scale additive manufacturing

Advancements in large-scale 3D printing are expanding the size limitations of printed objects. From architectural-scale structures to large industrial components, these technologies are opening new possibilities for on-site, on-demand manufacturing of large parts.

Hybrid manufacturing systems

Combining additive and subtractive manufacturing processes in a single machine, hybrid systems aim to leverage the strengths of both approaches. These systems can 3D print near-net-shape parts and then machine them to final tolerances, addressing some of the post-processing challenges while maintaining the design freedom of additive manufacturing.

4D printing

An evolution of 3D printing, 4D printing incorporates materials that can change shape or properties over time in response to external stimuli like heat, moisture, or light. This technology could enable self-assembling structures, adaptive components, and new possibilities in fields like biomedical engineering and responsive architecture.

Sustainable practices

Future developments are focusing on further reducing the environmental impact of 3D printing. This includes the development of biodegradable materials, improved recycling processes for print waste, and more energy-efficient printing technologies.

Standardization and certification

To address regulatory challenges, industry stakeholders are working towards standardized processes and testing methodologies for 3D printed parts. These efforts aim to streamline certification processes and increase confidence in the reliability and consistency of additively manufactured components.

Conclusion

As these innovations continue to develop, 3D printing is poised to play an increasingly central role in manufacturing across industries. The technology's ability to enable complex designs, customize products, and produce parts on-demand aligns well with broader trends towards more agile, sustainable, and localized production. While challenges remain, the ongoing advancements in materials, processes, and supporting technologies suggest a future where additive manufacturing becomes an integral part of the industrial landscape, complementing and in some cases replacing traditional manufacturing methods.

The journey of 3D printing from a rapid prototyping tool to a versatile manufacturing technology has been remarkable, and its future evolution promises to be equally transformative. As industries continue to explore and push the boundaries of what's possible with additive manufacturing, we can expect to see new applications, business models, and innovations that will reshape the way we design, produce, and consume goods in the years to come.

To gain a deeper understanding of how 3D printing is benefiting various manufacturing processes, we recommend reading our comprehensive guide on the benefits of 3D printing in manufacturing. This resource provides valuable insights into how businesses can leverage additive manufacturing to enhance their production capabilities and stay competitive in today's rapidly evolving industrial landscape.

Become an industry leader with UltiMaker

3D printing is not merely a complementary technology, it is reshaping the manufacturing landscape. At the cutting edge, UltiMaker’s Factor 4 empowers companies to innovate rapidly, cut costs, and create complex designs and paves the way for a more agile and efficient future.

If you want to know how UltiMaker can help you change the game for your business don’t hesitate to contact us and our team of experts would be more than happy to reach out!