Additive manufacturing (AM), commonly known as 3D printing, is no longer just an experimental tool—it has become a strategic asset in the automotive industry. Major original equipment manufacturers (OEMs) such as Toyota, Ford and General Motors are incorporating AM into their production workflows to enhance flexibility, reduce costs, and accelerate innovation.
Yet, despite increasing adoption, the complete industrialization of AM remains an untapped opportunity that could transform how cars are designed, built, and delivered.
Leading OEMs understand the value of using AM to mitigate supply chain disruptions, address factory mishaps, reduce production time, or save costs. However, the long-term benefits of AM extend beyond emergency fixes and require complete integration into daily manufacturing processes.
At the same time, OEMs face a shortage of workers as legacy expertise ages out of the workforce and younger generations choose different career paths. For younger workers attracted to tech-savvy fields, shifting to AM is a draw for working with leading-edge technology.
Integrating AM within automotive manufacturing leads to long-lasting efficiencies and offers a more resilient and sustainable process.
AM’s Evolving Role in Automotive: From Crisis Tool to Strategic Asset
Currently, when production disruptions occur, OEMs turn to AM to solve their issues in real time. By incorporating AM directly into these processes, OEMs gain increased preparedness, a greater ability to avoid unforeseen circumstances, and improved agility and efficiency.
Valiant TMS, a global automation and tooling supplier, demonstrates how integrating AM into core manufacturing processes can yield measurable benefits. Initially used for rapid prototyping, Valiant TMS quickly expanded its AM use to tooling, replacing traditionally machined parts with 3D-printed alternatives.
The results were compelling:
- Lead times dropped from 4–6 weeks to just 3 days.
- Costs decreased by 150% (primarily due to reduced material waste and machining time).
- Supply chain risks were minimized, thanks to in-house production capabilities.
This hybrid manufacturing approach—leveraging both AM and traditional methods—offers significant advantages: reduced inventory, streamlined logistics, and the ability to produce parts on-demand at or near the point of need.
In times of uncertainty, especially with changing tariff policies, AM offers manufacturers resilient and agile options to ensure continuity and responsiveness to market shifts. Combining traditional manufacturing with additive manufacturing creates a hybrid environment for on-demand production, reducing inventory and logistical burdens.
At the same time, manufacturers reduce costs and lead times, leading to improved efficiencies, particularly in tooling, as AM is used to produce custom jigs, fixtures, molds, and dies quickly and cost-effectively.
General Motors has realized the value of adding AM to its tooling processes. Recently, they used AM to improve their in-plant process, including developing solutions for employees who work on the assembly line. For example, at their Lansing Delta Township Assembly, line operators previously used a metal fixture to prop open vehicle hoods before attaching them to their hinges. These fixtures, however, typically weighed 14 pounds – heavier than the 10-pound limit for a one-hand lift. The team was able to use AM to lighten the part, developing a new, lighter, and ergonomic design with similar use case capabilities as the original.
For several years, GM has evaluated AM’s impact on its production, and it is now being incorporated into its entire tooling process. In 2024 alone, GM executed over 5,400 new additive manufacturing projects, with more to come in 2025.
Attracting a New Workforce
According to Deloitte, by 2033, US manufacturers could see a net need for as many as 3.8 million jobs, and more than 1.9 million of these jobs could go unfilled if workforce challenges are unresolved. As OEMs continue to increase investments in manufacturing, there’s a growing need to fill those empty jobs. Despite this need, since 2019, Gen Z’s share of the manufacturing workforce has declined (to 7 from 8 percent), even though more than 20 million Gen Zers reached adulthood in the intervening years.
McKinsey reported that increasing engagement with technology can improve younger workers’ attraction to and the likelihood of remaining in a manufacturing role, especially as digitalization and technology are rapidly reshaping the skillsets of today’s workforce.
General Motors is using its AM investments to attract next-generation talent. For example, anyone familiar with computer-aided design can quickly prep designs and run them through an AM printer, eliminating the need for extensive manual labor and offering safer working environments.
Automakers that incorporate AM into their processes have a chance to attract, upskill, and retain workers more effectively through new technologies. As older workers retire and new generations seek roles that involve innovative technologies, the industry urgently needs a workforce adept in digital technologies.
Additive Manufacturing Is Shaping the Next Industrial Revolution
As the automotive industry undergoes one of the most significant transitions in its history—from combustion engines to electric vehicles, from manual labor to smart factories—additive manufacturing is emerging as a critical enabler.
To remain competitive, agile, and future-ready, automotive manufacturers must move beyond the tactical use of AM and make it a foundational element of their production strategies. In doing so, they’ll unlock unprecedented efficiency, innovation, and resilience levels while attracting the next generation of skilled talent.
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Fadi Abro, StratasysStratasys
Fadi Abro is the Sr. Global Director – Automotive & Mobility for Stratasys. For more information, visit stratasys.com.