Additive Manufacturing Trends To Watch In 2025

The AM market is set to continue growing at a rapid rate thanks to increasing adoption across sectors. Forecasts suggest the market will be valued at 90 billion by 2032, with an annual growth rate of over 20%. Key drivers include:

• Advancements in 3D printing technology, which have opened doors for new applications in industries like aerospace, healthcare, and automotive
• A stronger emphasis on sustainable manufacturing, which has pushed companies to turn to AM to cut waste and lower their energy consumption
• Increasing consumer demand for customized parts—this is extremely costly and time-consuming to achieve with conventional manufacturing methods

There's no doubt about it—the artificial intelligence (AI) era is here. This technology is changing how industries operate, and in the next year and beyond, 3D printing trends will be no different. Here are some of the ways AI and related innovations like machine learning (ML) will integrate into AM processes:

• Using predictive analytics, ML algorithms will predict potential defects in new parts. This will lower failure rates and improve product quality—even with customizable and configurable parts.
• Generative design tools will become smarter and more accurate. Engineers will use AI to generate lightweight designs optimized for their purpose. These designs will feature organic shapes that ensure parts meet the required specifications without excess materials—a feat almost impossible to achieve through manual design.
• AI will boost efficiency and mitigate risk with process automation. This will result in shorter lead times and increased scalability.

Simulation tools allow engineers to predict how materials will behave during the printing process and under real-world conditions. This means there's less or no need to produce physical prototypes, which can be time-consuming and costly. In 2025, simulation will become more advanced and integral to AM. Developments to watch include:

• Updates to thermal simulations, which model temperature stress to produce parts that don't warp or crack under extreme conditions. This is particularly important when it comes to 3D printing using metal.
• Multi-material behaviour prediction, where new platforms will accurately predict how different materials will behave and interact during the printing process and in real-world applications. This will ensure compatibility and performance.
• Virtual design validation, which will give engineers an opportunity to test whether their structures meet key requirements before physical production begins.

Decentralized manufacturing positions production closer to end-users rather than at a central hub. This approach reduces transportation costs and enables faster delivery—it's a win for both customers and businesses. In 2025 and beyond, more and more companies will make the switch and reap the following benefits:

• Greater supply chain resilience, as localized manufacturing minimizes the impact of disruptions caused by global issues
• More viable on-demand production, where AM hubs enable just-in-time manufacturing (companies can then spend less on inventory storage)
• Scalable customization, which will allow manufacturing to cater to local market preferences without significant cost increases