The global manufacturing landscape is undergoing a seismic shift, driven by disruptions to traditional supply chains, material shortages, and an increasing demand for agile and efficient production methods. Amidst these challenges, 3d Printing On Demand has emerged as a powerful and transformative solution. This innovative approach to manufacturing is not just streamlining operations; it’s paving the way for unprecedented product innovation and faster time-to-market, capturing the attention of industries worldwide. The optimism surrounding this technology is palpable, evidenced by the recent public debuts of companies like Fathom, Shapeways, and Xometry, with Fast Radius soon to follow.
This new wave of digital manufacturing companies is deeply rooted in software and advanced digital technologies, with industrial 3D printing at its core. They are not merely promising quicker and more localized part production; they are delivering comprehensive digital solutions that empower businesses to achieve significant cost savings through product innovation and accelerated development cycles across virtually every product category.
“There is a growing recognition that the traditional infrastructure for designing, producing, and distributing goods is no longer adequate for today’s dynamic needs – it’s inflexible, wasteful, outdated, and unsustainable,” notes Lou Rassey, co-founder and CEO of Chicago-based Fast Radius.
Fast Radius’s cutting-edge microfactory in Chicago’s Goose Island showcases advanced industrial 3D printers from Carbon and HP, alongside digitally integrated CNC machines, all operating under their Cloud Manufacturing Platform. This facility is poised to manufacture critical components for diverse sectors, including electric vehicles, medical devices, healthcare, and consumer goods. The World Economic Forum has recognized Fast Radius as one of the top nine factories globally leading the charge in implementing “Industry 4.0” technologies.
The Spectrum of Digital On-Demand Manufacturing
While the term “on-demand digital manufacturing” often groups various approaches together, the reality is a diverse ecosystem of companies offering distinct methodologies in 3D printing, Industry 4.0 integration, and supply chain modernization.
At one end of the spectrum, platforms like Shapeways and Sculpteo, a BASF subsidiary, provide user-friendly online interfaces where anyone can upload designs and initiate 3D printing. This 3D printing on demand model prioritizes ease of access, enabling users to upload digital part files, select materials, and receive finished parts or prototypes within hours or days. This streamlined, consumer-centric approach democratizes manufacturing, facilitating the creation of everything from product prototypes to intricate architectural models.
Conversely, companies such as Materialise, a publicly traded entity since 2014, cater to a broader enterprise clientele with software solutions that empower businesses to manage their own in-house 3D printing operations. Their software also streamlines order tracking and production for on-demand 3D printing services. Materialise itself operates one of Europe’s largest 3D printing facilities, featuring six distinct 3D printing technologies to meet diverse client needs.
Fathom, initially a contract manufacturer specializing in small to medium volumes, proactively adopted innovative methods, including 3D printing, early on. While still offering traditional manufacturing services, Fathom distinguishes itself by integrating these with a comprehensive end-to-end digital production workflow.
“Our key differentiator lies in our extensive industry experience and deep-rooted relationships with our customers,” explains Ryan Martin, CEO of Fathom. “We are dedicated to providing large enterprise clients with customized solutions to address their unique manufacturing challenges.”
Fast Radius uniquely blends software-driven services, engineering proficiency, and state-of-the-art manufacturing facilities. As one of the few on-demand manufacturers to own and operate its production facilities, Fast Radius achieves seamless integration between its software solutions and automated production processes.
Their proprietary software offers intelligent design feedback, material and technology guidance, and full transparency throughout the production cycle. However, Lou Rassey emphasizes that on-demand manufacturing is just one facet of their offerings. “We specialize in creating custom microfactories tailored to specific customer needs, strategically located to optimize supply chains and enhance flexibility.” For example, Satair, an Airbus subsidiary, utilizes the Fast Radius Virtual Warehouse to digitally store part designs, enabling immediate on-demand manufacturing, thereby reducing physical storage needs and minimizing excess inventory.
The proliferation of on-demand digital manufacturers has created a complex landscape for businesses seeking the right partner. Platforms like Xometry and Craftcloud address this challenge by acting as online marketplaces. These platforms allow customers to upload their digital designs and receive competitive bids from a global network of manufacturing partners.
“Customers often prioritize speed and cost-effectiveness for their 3D printing projects,” states Mathias Plica, CEO of Craftcloud. “We connect them with local partners who possess the expertise to deliver the required materials and quality standards efficiently.”
Irrespective of their specific business model, these companies share a common thread: the application of smart manufacturing technologies to create highly automated processes from design to fulfillment. This encompasses cloud computing, Artificial Intelligence (AI), the Internet of Things (IoT), machine learning, big data analytics, digital simulation, and, crucially, 3D printing, also known as additive manufacturing.
Champions of Additive Manufacturing and 3D Printing on Demand
Fathom, despite its physical headquarters in Heartland, Wisconsin, and its extensive infrastructure of 90 industrial-grade 3D printers for both plastic and metal parts across 12 U.S. facilities, recognizes its most valuable asset may be its team of experts.
“Companies often turn to us seeking guidance on leveraging additive manufacturing,” says Martin. “In many instances, we are introducing companies to the potential of additive manufacturing for the first time, which represents a significant growth area for us. Recently, a major automotive client approached us for our engineering expertise to explore new applications beyond just prototyping.”
The core message from on-demand digital manufacturers is clear: customers don’t need in-depth 3D printing knowledge to reap the benefits of its inherent flexibility, speed, and cost advantages. Furthermore, businesses can access these advantages without the need for substantial investments in expensive 3D printing equipment or specialized engineering teams. 3D printing on demand provides a practical entry point, allowing companies to obtain parts, prototypes, and tools that are lighter, stronger, and often more cost-effective than those produced using traditional manufacturing methods.
Large enterprises are increasingly opting for on-demand 3D printing to access a broader spectrum of materials and technologies than would be feasible to maintain in-house. Fathom’s client roster includes industry giants like Tesla, 3M, Google, and Amazon. Shapeways lists Target and prosthetic manufacturer Fillauer among its clients, while Xometry proudly serves engineers at Bosch, NASA, and BMW.
Fast Radius offers its Additive Launch service, designed to assist clients in harnessing the latest 3D printing technologies and design tools to accelerate product development cycles.
“We have partnered with companies like Rawlings, Steelcase, and Aptiv to bring to market innovative products that are only achievable through additive manufacturing,” Rassey highlights. The revolutionary REV1X Rawlings baseball glove, for example, features internal 3D printed padding in the thumb and pinky, significantly reducing glove weight without compromising protection or durability, according to Rawlings.
Volvo recently collaborated with Materialise to streamline the production of lighter, more efficient manufacturing tools and fixtures for its factories. Bell Helicopter Textron turned to Stratasys Direct, the on-demand manufacturing division of 3D printer manufacturer Stratasys, to 3D print flight-certified components. This initiative resulted in a 13% weight reduction and a remarkable 75% decrease in manufacturing lead time, as reported by the company.
Beyond advancements in 3D printing expertise, the growth of on-demand manufacturers is further propelled by progress in additive manufacturing software and the 3D printers themselves. These technologies, along with other Industry 4.0 components, are now more mature, dependable, and affordable, notes Rassey. This maturity enables companies like Fast Radius and others to build sustainable and profitable business models around these cutting-edge tools.
“With Industry 4.0 gaining momentum, we are on the verge of a substantial growth phase,” concludes Martin. “Product lifecycles are dramatically shorter than they were just five years ago, and businesses require an agile, on-demand advanced manufacturing partner capable of responding quickly and meeting all their requirements without compromising quality.”
The expanding landscape of service providers serves as compelling evidence that more companies are recognizing the value of agile digital manufacturing platforms and the advantages of transitioning from traditional to digital manufacturing through trusted on-demand service partners.
