Additive Manufacturing
Additive Manufacturing is revolutionizing how products are designed, prototyped, and manufactured. By building objects layer by layer, this innovative approach allows for the creation of complex geometries, lightweight structures, and customized components that are often impossible to achieve with traditional manufacturing methods. As industries seek greater flexibility and efficiency, additive manufacturing continues to grow in importance.
In this glossary entry, we’ll explore what additive manufacturing is, how it works, the different types, and how Siemens solutions like NX for Manufacturing support end-to-end additive workflows.
What is Additive Manufacturing?
Additive manufacturing (AM) is a manufacturing process that creates three-dimensional objects by adding material layer by layer based on digital 3D models. Unlike subtractive manufacturing, which removes material from a solid block, additive manufacturing builds up material only where it’s needed.
Often used interchangeably with 3D printing, additive manufacturing spans much more than prototyping—it now supports functional part production in industries like aerospace, automotive, medical, and industrial equipment.
How Does Additive Manufacturing Work?
The additive manufacturing process begins with a digital design, usually created in CAD (Computer-Aided Design) software. This digital file is then sliced into layers and translated into machine instructions for a 3D printer or industrial AM system.
Here are the basic steps:
- Design: A 3D model is created in CAD software like NX for Manufacturing, which supports design optimization for additive processes.
- Preparation: The design is converted into a printable format (such as STL), sliced into layers, and optimized with settings for temperature, speed, and material use.
- Printing: A 3D printer builds the object layer by layer using materials like polymers, metals, or ceramics.
- Post-Processing: The printed part may undergo processes like cleaning, curing, heat treatment, or machining to meet functional and surface quality requirements.
Advanced solutions like Siemens NX for Manufacturing integrate design, simulation, and print preparation in a single environment—streamlining the entire additive workflow from concept to production.
What Are the 7 Types of Additive Manufacturing?
According to the ISO/ASTM 52900 standard, there are seven recognized categories of additive manufacturing processes:
- Material Extrusion
Commonly used in desktop 3D printing, this method involves extruding melted thermoplastic filament through a heated nozzle (e.g., Fused Deposition Modeling - FDM). - Vat Photopolymerization
Uses a light source (usually UV) to cure liquid photopolymer resin layer by layer (e.g., Stereolithography - SLA). - Material Jetting
Droplets of material are deposited and cured with light or heat, similar to inkjet printing but in three dimensions. - Binder Jetting
A liquid binder is selectively deposited onto a powder bed to bond particles together. Used for metals, ceramics, and sand molds. - Powder Bed Fusion
Utilizes a laser or electron beam to selectively melt powder particles (e.g., Selective Laser Melting - SLM or Electron Beam Melting - EBM). - Sheet Lamination
Layers of sheet material (metal or paper) are cut and bonded together, often used for quick and inexpensive prototyping. - Directed Energy Deposition (DED)
Metal powder or wire is fed into a focused energy source (laser, electron beam) that melts the material as it’s deposited. Suitable for large-scale metal parts and repairs.
Siemens’ NX for Manufacturing supports simulation and path planning for DED and Powder Bed Fusion, enabling manufacturers to optimize builds and reduce trial-and-error iterations.
What Is the Difference Between 3D Printing and Additive Manufacturing?
While often used synonymously, 3D printing and additive manufacturing have subtle differences in meaning and context.
- 3D Printing typically refers to desktop or consumer-level technologies for rapid prototyping or hobby use. It emphasizes convenience, ease of use, and accessibility.
- Additive Manufacturing, on the other hand, is a broader term used in industrial settings. It includes high-performance technologies for producing functional parts with strict mechanical, thermal, and dimensional requirements.
In short: all 3D printing is additive manufacturing, but not all additive manufacturing is 3D printing in the traditional sense.
Benefits of Additive Manufacturing
Additive manufacturing offers a range of benefits that make it attractive to modern manufacturers:
- Design Freedom
AM enables the creation of complex geometries, internal structures, and organic shapes that are impossible with traditional methods. - Customization
It allows for personalized products without the need for costly tooling changes—ideal for medical implants, dental prosthetics, and consumer goods. - Lightweighting
Topology optimization and lattice structures help reduce weight while maintaining strength, especially valuable in aerospace and automotive applications. - Reduced Waste
AM is inherently material-efficient, using only what is needed to build the part. This leads to sustainability gains and cost savings. - Shorter Lead Times
Rapid prototyping and on-demand production eliminate the need for molds or long setup times, speeding up product development cycles. - Digital Manufacturing Integration
AM can be fully integrated into digital manufacturing environments, enabling simulation, traceability, and real-time monitoring. Tools like Siemens Opcenter and NX for Manufacturing support closed-loop manufacturing workflows.
What Is an Example of Additive Manufacturing?
A compelling example of additive manufacturing in action is metal 3D printing for aerospace turbine components. These parts often require internal cooling channels and lightweight designs—features that are difficult or impossible to achieve through traditional machining.
Using Powder Bed Fusion, engineers can produce a single lightweight turbine blade with complex internal geometries, reducing weight and improving performance. Tools like NX for Additive Manufacturing allow for simulation of thermal stresses, build strategies, and support structure optimization before printing even begins.
Other real-world examples include:
- Customized dental crowns and orthodontics using resin-based Vat Photopolymerization.
- Topology-optimized automotive brackets manufactured with DED for strength and reduced mass.
- Rapid prototyping for consumer electronics during design iteration phases.
Additive Manufacturing is more than a trend—it’s a transformative production method reshaping industries through innovation, efficiency, and flexibility. From rapid prototyping to full-scale industrial production, the ability to design and produce parts layer by layer unlocks new levels of creativity and performance.
As a reseller of Siemens solutions, we offer powerful tools like NX for Manufacturing, which supports a fully integrated additive manufacturing workflow—from generative design and simulation to build preparation and machine output. Whether you’re exploring new production methods or scaling advanced AM operations, Siemens technology enables you to do it faster, smarter, and with confidence.