Introduction
In recent years, additive manufacturing (AM) has shifted from a niche technology used primarily for prototyping and model creation into a robust solution for producing high-quality, precision-engineered end-use components across high-performance industries such as space, aerospace, industrial, motorsport, automotive and defence. Unlike traditional manufacturing methods, which often rely on subtractive processes or significant tooling investment, AM builds components layer-by-layer, unlocking possibilities for innovative designs, improved performance and enhanced material efficiency. At the Digital Manufacturing Centre (DMC) our engineers have years of experience and have been trained to fully understand the key properties and capabilities of AM and critically think differently about how parts are conceived, manufactured and utilised. There are many instances where using AM has key advantages over other production methods, however only when our AM engineers are engaged at the forefront of the design process can the engineering challenge be approached holistically and the incredible benefits of using AM be fully realised.
Low Volume On-Demand Production
One of the standout advantages of additive manufacturing (AM) over traditional methods, such as casting or machining, is its efficiency and flexibility in low-volume production. Unlike conventional manufacturing, which often requires expensive tooling and moulds that only become cost-effective at high volumes, AM can economically produce smaller batches, making it ideal for custom parts or short production runs. This adaptability allows for swift implementation and not only reduces upfront costs but also allows for rapid production cycles, enabling designers to iterate and innovate without the lengthy lead times and cost associated with retooling.
Furthermore, AM processes are highly automated and can operate autonomously and continuously, meaning production can run 24/7 with minimal human oversight. This “always-on” capability brings greater productivity, creating a streamlined production process that supports faster time-to-market for new products, reduced labour costs and the flexibility to scale production on demand. This superior responsiveness allows for parts to be produced as needed, reducing the requirement for large inventories and storage and, if set up correctly, can support localised manufacture to enable production closer to end users thereby reducing shipping costs and further supporting just-in-time manufacturing. Through these benefits, AM opens the door for more agile and responsive manufacturing approaches, setting a new standard for efficiency in today’s fast-paced market while minimising the environmental impact.
Material Efficiency
Additive manufacturing (AM) stands apart from traditional methods by its efficiency in material usage, as it builds components layer by layer using only the exact amount of material needed for each part. In contrast, traditional manufacturing processes, such as machining, rely on subtractive techniques, where material is removed from a larger block to create the final shape. This approach often leads to substantial material waste—sometimes up to 80%— especially when producing complex shapes or high-precision components and lightweighting. This waste not only drives up raw material costs but also incurs additional disposal expenses and environmental impacts and energy usage.
Furthermore, subtractive processes generally require specialised machines, such as CNC mills or lathes, and custom tools that need regular maintenance and replacement, adding both direct and indirect costs. Skilled labour is also essential to ensure accuracy, which means high labour costs and potential delays due to the availability of trained personnel. In contrast, AM systems automate much of the process, reducing the need for specialised labour and equipment while producing parts with minimal waste. This combination of precise material usage, reduced labour reliance and less waste makes AM an efficient, cost-effective alternative to traditional manufacturing for both prototyping and end-use products.
AM Design Advantages
Designing specifically for additive manufacturing (AM) allows DMC engineers to unlock structural and geometric possibilities that are unachievable with traditional manufacturing methods. AM’s layer-by-layer approach enables the creation of intricate, optimised internal structures such as lattices, honeycombs and other complex geometries that balance strength with minimal material usage often drawing on nature's own evolution. These lightweight structures can significantly reduce part weight while maintaining or even enhancing structural integrity, making them ideal for industries like aerospace, automotive and defence, where weight savings are critical.
Unlike conventional manufacturing, where complex internal features are difficult or impossible to machine, AM can produce these features in a single build, streamlining the process and removing the need for assembly. Furthermore, design-for-AM approaches encourage innovation by allowing more freedom in form and function, opening doors to custom, performance-optimised parts that not only meet engineering requirements but also save material, reduce production costs and support sustainable manufacturing practices.
To fully leverage these advantages, it is essential to design components with additive manufacturing capabilities in mind from the very beginning. Traditional design approaches, often geared toward conventional machining or casting, can restrict the potential of AM and limit its benefits.
Conclusion
To make the most of AM’s capabilities, engineers, product designers and manufacturers need to challenge established processes and recognise AM as an integral part of their design strategy. This shift calls for a reimagining of what is possible in terms of shape, structure and material use, encouraging a more innovative, adaptable mindset in product development. By prioritising AM-specific design practices, industries can not only drive their own competitiveness and innovation but also contribute to a manufacturing landscape that values both performance and environmental responsibility. The future of AM is bright, and it starts with a commitment to designing for AM from the beginning – this is the underpinning philosophy of the DMC, an engineering-led contract manufacturing facility that can support you end to end on the journey where it begins with our engineers optimising your design to leverage AM to solve your problem.
