Aerospace manufacturers use metal 3D printing to produce lightweight engine components with complex internal designs.

For example, GE Aerospace consolidated approximately 20 components of its LEAP engine fuel nozzle into a single printed piece, reducing its weight by 25%. This approach also reduces the number of joints and makes assembly simple.

Beyond producing vehicle components, metal 3D printing is helping automakers improve their manufacturing processes.

Manufacturers can create injection molds with internal cooling channels that follow the shape of the parts being produced. These designs improve temperature control, shorten production cycles, reduce defects, and add to the factors that make large-scale automotive manufacturing efficient.

Following an injury or surgery, a patient may need a metal implant to replace part of their skull. Using medical scans, manufacturers can 3D-print a titanium implant matched to the patient’s anatomy. Another application is porous titanium spinal implants, which encourage bone ingrowth and help secure the implant in place.

Aging oil and gas equipment is difficult to maintain when manufacturers discontinue replacement parts.

With metal 3D printing, operators can reproduce the parts they need even if those parts are no longer available. For example, Shell has manufactured replacement impellers for equipment operating at its facilities. This has helped them extend the service life of existing machinery.

The jewelry industry has seen a great transformation from the adoption of 3D metal printing. Some jewelry designers can now print directly in gold and platinum instead of relying entirely on traditional casting.

The Austrian jewelry brand Boltenstern, for example, uses metal 3D printing to produce bracelets with interconnected links that move naturally around the wrist. This allows jewelers to create movable designs without manufacturing and joining each link separately.

Shipbuilders are also exploring ways to manufacture large metal components without traditional casting.

In 2017, a consortium involving Damen Shipyards produced the WAAMpeller, a 3D-printed bronze-alloy propeller. After testing it on a tugboat, Bureau Veritas granted class approval, demonstrating that printed metal components can meet demanding maritime performance requirements.

Metal 3D printing is increasingly being used in public infrastructure. From the stainless-steel pedestrian bridge that was built in Amsterdam using robotic welding arms to custom steel connectors for building structures, the technology is expanding construction possibilities tremendously.

With 3D metal printing in construction, structural elements are no longer limited to straight beams, standardized joints, and rigid geometries. Engineers can now develop structural components tailored to specific loads and architectural requirements.

Heat buildup is a persistent challenge in servers and other high-powered electronics. To solve this issue, manufacturers can use metal 3D printers to produce copper heat sinks with channels that circulate cooling fluid near hot components.

Some printed heat sinks have no separate joints or gaskets, reducing the potential leak points inside servers.

Metal 3D printing is making its way into nuclear fuel production, an area where every component must meet strict safety standards.

In 2024, Westinghouse manufactured its 1000th 3D-printed fuel flow plate for VVER-440 nuclear fuel assemblies. The achievement demonstrated that additive manufacturing could support serial production of safety-related nuclear components.

In dentistry, metal 3D printing allows dental laboratories to manufacture patient-specific restorations and prosthetic frameworks using digital scans.

Dental technicians can adjust the shape and fit of each restoration before production, reducing the need for extensive manual fabrication. The finished metal components can then undergo polishing and other treatments before clinical use.

Metal 3D printing isn’t going to replace casting, machining, or other established manufacturing methods. Its value lies in giving manufacturers another way to solve production challenges, whether that means making parts on demand or tailoring them to specific requirements. As these applications grow, more industries are likely to adopt the technology.