White Paper: Material Innovation in Additive Manufacturing: Challenges and Breakthroughs

Executive Summary

Materials are the foundation of additive manufacturing (AM), governing performance, reliability, and regulatory compliance. As 3D printing expands from prototyping into production, the material landscape must evolve in parallel. The 2023 Jabil survey of 200 AM decision-makers reveals that while plastics dominate current usage (97%), metals (60%), composites (44%), and ceramics are increasingly critical. Yet, the survey also uncovers deep constraints: 90% of respondents cite unavailable materials as a barrier to scale, and 74% identify material cost as a leading financial obstacle.

This white paper explores the current state of AM materials—including adoption trends, innovation in custom-engineered feedstocks, and systemic limitations in cost, certification, and supply chain access. It also addresses the economic and technical barriers that inhibit scaling AM beyond niche applications. Finally, it outlines pathways for manufacturers to overcome these constraints through strategic sourcing, R&D collaboration, and service partnerships with organizations like RapidMade, which specialize in certified, production-grade material integration.

Material Science: Adoption, Innovation, and Limitations

Material Utilization Across Industrial AM

The survey reveals the hierarchy of material usage in additive manufacturing:

• Plastics/Polymers: Used by 97% of respondents, including both standard thermoplastics (PLA, ABS) and advanced engineering polymers (PEEK, ULTEM).
  
  
• Metals: Adopted by 60%, with high-strength alloys such as stainless steel, Inconel, titanium, and aluminum critical in aerospace, automotive, and defense applications.
  
  
• Composites: Used by 44%, often combining carbon or glass fibers with polymers for enhanced mechanical and thermal properties.
  
  
• Ceramics and Glass: Represent a smaller share (~14–17%) but play essential roles in dental, microelectronics, and high-temperature environments.
  
  

While plastics dominate due to processability and cost, 96% of survey participants express a strong interest in using certified metal materials—underscoring a significant gap between application demand and material availability.

Custom-Engineered Materials and Application-Specific Performance

A major shift is the rise of custom-engineered materials, reported by 66% of organizations. These materials are specifically formulated to meet performance and regulatory requirements in high-value applications.

Use cases include:

• Aerospace: Aluminum alloys designed for fatigue resistance and weight reduction.
  
  
• Medical: Biocompatible polymers and porous titanium structures for implants.
  
  
• Electronics: Thermally conductive or RF-shielded materials for enclosures.
  
  
• Automotive: High-impact thermoplastics for interior panels and lightweight assemblies.
  
  

Custom materials are engineered for attributes such as:

• Enhanced tensile strength and modulus
  
  
• Controlled thermal expansion
  
  
• Specific color and surface finish
  
  
• Compliance with UL 94 V-0, ISO 10993, or ASTM F42 standards
  
  

These materials often require proprietary formulation, specialized processing profiles, and rigorous validation—factors that increase time-to-market and cost but are essential for mission-critical applications.

Certification and Access Constraints

Despite rising interest, several bottlenecks constrain the broader use of advanced materials:

• 90% of respondents state that the materials they need are not currently available in a printable or certified form.
  
  
• 74% cite cost as a primary constraint, especially for metals and high-performance polymers.
  
  
• 49% report that it takes too long to develop and qualify materials for their specific requirements.
  
  
• 27% cannot proceed with adoption due to lack of available certifications.
  
  

The imbalance between material innovation and regulatory readiness is particularly acute in aerospace, healthcare, and electronics. Without certified data for fatigue life, biocompatibility, or thermal cycling, AM parts cannot replace legacy components or meet OEM qualification protocols.

Economic and Technical Barriers to Scaling AM

Financial Obstacles: Cost of Materials and Equipment

As material demands rise, so do cost pressures. The survey highlights that:

• Material costs are the number one financial hurdle, cited by 79% of respondents.
  
  
• These costs have quadrupled in visibility since 2021, signaling a worsening constraint on growth.
  
  

Materials such as titanium and ULTEM command high premiums due to powder preparation, particle size distribution control, and strict process windows. Furthermore, polymer feedstocks often require pre-conditioning or support materials that add cost and complexity.

Capital investment is another burden:

• 63% of respondents report that AM system cost is a barrier.
  
  
• Metal printers, inert environments, and industrial-scale post-processing systems can exceed $1 million per unit.
  
  

These financial dynamics prevent many companies from experimenting with high-value materials and constrain their ability to scale successful pilot programs.

Post-Processing and Workflow Challenges

Once printed, AM parts often undergo multiple post-processing steps, including:

• Support removal
  
  
• Thermal treatment (e.g., sintering, annealing)
  
  
• Surface finishing
  
  
• Inspection and testing
  
  

According to the survey:

• 48% of respondents list post-processing costs as a scaling issue.
  
  
• Part quality concerns, while reduced from 37% (2021) to 12% (2023), still affect adoption in regulated environments.
  
  

Lack of automation and standardization in post-processing remains a challenge, particularly for materials that require tight dimensional tolerances or surface specifications.

System Integration and Talent Gaps

Another often-overlooked barrier is software and systems integration:

• 42% of participants struggle to connect AM workflows to their existing MES, ERP, or PLM platforms.
  
  
• This limits part traceability, digital thread continuity, and data collection needed for qualification.
  
  

Moreover:

• 29% of respondents cite a shortage of in-house AM expertise.
  
  
• Engineers familiar with machining or injection molding often lack training in Design for Additive Manufacturing (DfAM), thermal simulation, and support structure design—all crucial for optimizing material behavior during and after printing.
  
  

Organizations that do not invest in interdisciplinary skill development or external support risk material misuse, part failure, and stalled scale-up efforts.

Conclusion and Recommendations

Material science is both the engine and the anchor of additive manufacturing. While usage of polymers remains strong, future growth hinges on access to cost-effective, certified, and application-optimized materials. The 2023 Jabil survey confirms that:

• There is a major gap between material demand and supply, especially for metals and regulated applications.
  
  
• Custom-engineered feedstocks offer promise but require long development cycles.
  
  
• Cost, certification, and systems integration remain major constraints for scaling AM with advanced materials.
  
  

To bridge these gaps, manufacturers must:

• Collaborate with material suppliers to co-develop certified solutions.
  
  
• Invest in workforce development focused on DfAM and post-processing.
  
  
• Integrate AM into enterprise systems to ensure traceability and quality control.
  
  
• Use external partners to supplement in-house material R&D and scalable production.
  
  

Strategic Material Support from RapidMade

RapidMade provides end-to-end additive manufacturing services with a strong focus on material innovation and certified production. With access to a broad library of polymers, composites, and metals—including those qualified for medical, aerospace, and industrial use—RapidMade helps clients match materials to applications with precision.

Capabilities include:

• Custom formulation and process optimization for mission-critical materials
  
  
• Expertise in DfAM for material-specific geometry and support strategies
  
  
• Scalable production with ISO 9001-certified quality systems
  
  
• Post-processing and testing for regulated compliance and field performance
  
  

If your organization is facing material constraints in AM—whether related to cost, qualification, or supply—RapidMade offers the experience, infrastructure, and technical depth to support your transition from prototype-grade polymers to production-grade certified materials. We are quite simply the best 3D printing service around.

Learn more at www.rapidmade.com