Understanding additive manufacturing: Technology & use cases

Additive manufacturing (AM), also known as 3D printing, is changing the way products are made. Instead of cutting or shaping material like traditional methods, AM builds objects layer by layer using digital 3D models. 

From aerospace and healthcare to automotive and consumer goods, 3d printing and additive manufacturing are helping manufacturers rethink how they design, build, and deliver products. In this article, we’ll take a closer look at additive manufacturing, its real-world applications, and the growing role of computer vision in advancing additive manufacturing. Let's get started!

What is additive manufacturing?

Additive manufacturing is a digital fabrication process used to create physical objects by depositing material layer by layer, following instructions from a 3D model. Starting with a computer-aided design (CAD) file, the model is sliced into thin cross-sections. These sections or layers guide a machine, like a 3D printer, to deposit materials such as plastic, resin, or metal until the object is complete.

With additive manufacturing technologies, it’s easier to create complex geometries, lightweight structures, and customized parts without specialized tools. It also supports rapid prototyping, letting teams test and refine designs faster, and enables on-demand production.

‍

Additive vs subtractive manufacturing

Before we dive into why additive 3D printing is making a difference, let’s quickly compare it to traditional subtractive manufacturing. 

Subtractive manufacturing creates parts by removing material from a solid block using tools like drills, lathes, or mills. It’s a common method in industries that require high precision and large production volumes.

Additive manufacturing takes the opposite approach. It builds parts layer by layer from a digital design, adding material only where needed. This makes it more efficient, reduces waste, and enables complex and customized designs that are challenging to achieve with traditional methods.

Why AM is transforming manufacturing

One of the key reasons additive production is being rapidly adopted is its ability to speed up product development and reduce waste. By building parts directly from digital designs, manufacturers can move from concept to prototype quickly.

Also, AM is efficient with materials, cutting waste by up to 90% compared to traditional manufacturing processes. On top of that, it enables mass customization and makes it easier to produce one-off or unique parts without the cost or delays of retooling.

These advantages are leading to a shift in how and where products are made. The additive manufacturing process makes it possible to localize production, reducing dependence on centralized factories and long supply chains. This is especially impactful in industries like aerospace, medical, and automotive, where fast turnarounds, precision, and adaptability are critical.

Key additive manufacturing processes

Additive manufacturing encompasses more than one process. It is a general term for a group of technologies related to 3D printing. Each specific type uses different materials and methods.

Here are some common examples of different additive manufacturing technologies:

• Fused deposition modeling (FDM): FDM is one of the most common additive 3d printing methods. It works by heating plastic filament and laying it down layer by layer to form a part. It’s affordable and easy to use, making it ideal for quick prototypes, though it’s not the best choice for high-detail or high-strength applications.
  ‍
• Selective laser sintering (SLS): SLS uses a laser to fuse powdered materials, usually nylon, into solid parts. It’s great for producing strong, functional components with complex shapes and doesn’t require support structures. The surface finish can be a bit rough, so post-processing is often required.
  ‍
• Stereolithography (SLA): SLA leverages an ultraviolet (UV) laser to harden layers of liquid resin into highly detailed parts. It’s known for being accurate and providing smooth finishes, which makes it popular in medical, dental, and design applications. However, the materials are often brittle and better suited for display or light-use items.
  ‍
• Binder jetting: Binder jetting sprays a binding liquid onto a bed of powder, layer by layer, to form a part. It’s a fast and scalable process, often used for making casting molds or decorative objects.
  ‍
• Material jetting: This method jets droplets of liquid material onto a surface and cures them with UV light. It produces highly detailed, full-color parts with smooth finishes, but the materials are not strong enough for functional use. It’s best for display models or medical guides.
  ‍
• Directed energy deposition (DED): DED works by feeding metal wire or powder into a focused energy source, like a laser, which melts the material as it’s applied. It’s commonly used to repair or add features to large metal parts, especially in aerospace and heavy industry. It’s less precise than other metal printing methods but great for large-scale work.

‍

High-impact use cases of AM by industry

Now that we have a better understanding of how additive manufacturing works, let’s explore some examples of how it’s being used across different industries to drive innovation and efficiency. 

For instance, in the aerospace sector, additive manufacturing processes are used to produce lightweight structural components that help reduce fuel consumption while maintaining strength and safety. Similarly, in healthcare, additive production enables the creation of custom implants, prosthetics, and surgical guides tailored to individual patients, improving both outcomes and comfort. 

Another area being enhanced by 3D printing is the automotive industry, where manufacturers use additive manufacturing technologies for rapid prototyping, functional testing, and low-volume production of tools and replacement parts. Meanwhile, in consumer goods, various brands are using additive 3d printing to offer personalized products and limited-edition items without the need for traditional molds.

So far, all the examples we've discussed are on a smaller scale, but additive manufacturing is also making an impact in large-scale applications like construction and architecture. In this space, industrial additive manufacturing machines are being used to build structural components, and even entire homes, layer by layer, using materials like concrete. These approaches can significantly cut down on construction time, reduce material waste, and lower labor costs. 

‍

Innovation and future trends of additive manufacturing

As additive manufacturing technologies continue to evolve, new trends are pushing the boundaries of what's possible. 

An interesting example is the use of AI-powered generative design, which creates optimized part geometries. Also, hybrid manufacturing techniques, which combine additive and traditional methods, are gaining traction because they bring together the precision of machining and the creative freedom of 3D printing. Sustainability is another growing focus, with new materials and processes aimed at reducing energy use and minimizing waste. 

At the same time, additive manufacturing is getting smarter. As additive manufacturing technologies integrate with digital twins, the Internet of Things (IoT), and smart factories, they are becoming more connected and intelligent. In fact, AM is considered a key enabler of Industry 4.0, supporting more adaptive, data-driven, and efficient manufacturing systems.

Advantages of additive manufacturing

Here’s a quick glimpse of the key benefits additive 3d printing offers across industries:

• Reduced waste and energy use: By adding material only where needed, the additive manufacturing process significantly cuts down on scrap and often uses less energy than traditional methods.
  ‍
• Lightweighting potential: 3d printing enables complex, internal structures that reduce part weight without sacrificing strength.
  ‍
• Part consolidation: Complex assemblies can be printed as a single part, reducing the need for multiple components, fasteners, and assembly time.

Challenges in additive manufacturing

While 3D printing offers many advantages, there are also a few limitations to consider. Here are some of the key challenges of additive production:

• Limited material availability: Not all materials work with every 3D printing process, which can restrict certain applications.
  ‍
• Speed vs. scale trade-offs: 3D printing is great for prototypes and small batches, but can be slow and costly for large-scale production.
  ‍
• Post-processing requirements: Many parts require additional steps, such as cleaning, curing, or finishing, which add time, labor, and cost.

Enhancing additive manufacturing with computer vision

Cutting-edge technologies like computer vision, a branch of AI that enables machines to understand and analyze images, are helping solve some of the challenges of 3D printing. Vision AI allows manufacturers to monitor prints in real time, detect defects early, and improve overall accuracy. 

When combined with AI in manufacturing, computer vision also supports predictive maintenance and process automation. For example, it can automatically pause a print job if a defect or material inconsistency is detected, reducing waste and avoiding failed builds.

‍

Key takeaways

Industries around the world are embracing additive manufacturing technologies to produce complex parts faster, with less waste and greater design freedom. Compared to conventional manufacturing, these additive manufacturing processes offer smarter, more sustainable solutions. As more manufacturers explore what 3D printing and additive manufacturing can do, the future of production is becoming more flexible, efficient, and innovative.

Want to learn more about AI? Explore our GitHub repository, connect with our community, and check out our licensing options to jumpstart your computer vision project. Find out how innovations like AI in retail and computer vision in healthcare are shaping the future.