Additive manufacturing has emerged as a cornerstone of the Artemis II mission and high-volume medical production, according to Brett Conner, chief manufacturing officer at the Society of Manufacturing Engineers (SME). Speaking on the current industrial state of 3D printing, Conner highlighted that the technology has transcended its origins in prototyping to provide critical flight hardware and over one million dental aligners daily.
The mission utilizes more than 200 additively manufactured parts, with the majority located on the Orion spacecraft. These components range from structural brackets and ducting to 12 metal Reaction Control System (RCS) thruster nozzle extensions. Produced in just three weeks on a single machine, these nozzle extensions were manufactured 40% faster than they would have been using traditional techniques.
This shift toward production-grade reliability marks a turning point for industrial operations. Unlike subtractive manufacturing, where material is removed from a block, additive processes build parts layer by layer. While the technology is 40 years old, Conner noted that improvements in dimensional accuracy and material properties now allow it to meet the load-bearing requirements of aerospace and medicine.
Artemis II mission showcases complex aerospace hardware
The Orion spacecraft relies on more than 150 polymer production parts, including a large external docking hatch cover. This six-piece assembly, measuring roughly one meter in diameter, uses a PEKK-based electrostatic-dissipative material. This specific material choice eliminates the need for secondary nickel plating or coatings to manage space-based electrostatic risks.
Engine efficiency has also benefited from these processes. While the RS-25 engines for early Artemis flights use refurbished hardware, future versions for Artemis V and beyond will feature 3D-printed pogo accumulator assemblies. By using selective laser melting, NASA and its partners have eliminated over 100 welds, reduced production time by 80%, and cut costs by approximately 35%.
Such advancements in aerospace often mirror developments in industrial and engineering stocks, where investors monitor the adoption of high-efficiency production methods. The ability to consolidate dozens of parts into a single printed object significantly reduces weight and points of failure in high-stress environments.
Mass customisation in medical and dental sectors
Outside of space exploration, the dental industry represents one of the largest applications of high-volume additive manufacturing. Companies currently print one million dental aligners every day. Rather than the aligner itself being the printed product, 3D printers create a precise tool in the shape of the patient’s teeth, which then serves as a mould for the final clear aligner.
Surgical implants also leverage 3D printing to create “trabecular” geometries that mimic the porous structure of natural bone. This allows human bone to grow directly into the implant, improving long-term stability and patient outcomes. These applications demonstrate the concept of “mass customisation,” where unique, patient-specific items are produced at an industrial scale.
This level of precision is increasingly supported by industrial connectivity and IoT sensors, which monitor machine performance to ensure quality across thousands of identical or customised cycles. For medical manufacturers, the ability to print at the point of care provides a significant logistical advantage.
Overcoming cost and workforce barriers in manufacturing
Despite these successes, Conner admitted that barriers to entry remain, particularly regarding capital expenditure and specialised training. High costs for industrial-grade metal printers and the raw materials they require can deter smaller firms. Furthermore, there is a persistent need for a workforce capable of “designing for additive manufacturing” (DfAM).
Qualification and certification also add layers of complexity. In sectors like aerospace or medical devices, the FAA or FDA must certify not just the final part, but the entire process—including the machine, the material batch, and the operator. These regulatory requirements ensure safety but necessitate a rigorous quality assurance framework inside the factory.
For many companies, the first step is implementing simple desktop printers for jigs, fixtures, and shop-floor tools. These “easy wins” allow engineers to familiarise themselves with the technology before scaling to metal systems. As the industry matures, the focus is shifting toward hybrid models that combine additive speed with the precision of subtractive machining.
Future outlook for industrial 3D printing
The long-term goal for space agencies like NASA involves “in-situ resource utilisation,” or using materials found on other planets to print components on demand. This would reduce the reliance on Earth-based resupply missions and enhance autonomy during deep-space exploration. On Earth, the trend leans toward further part consolidation and material innovation.
The success of the Artemis II hardware provides a roadmap for other sectors to follow. By reducing part counts and eliminating complex assembly steps, manufacturers can achieve lighter, stronger, and more cost-effective products. As software and hardware continue to integrate, 3D printing is expected to move from an alternative method to a standard requirement in complex assembly lines.
