Trendspotting: The State of Additive Manufacturing in 2024 – Insights from Formnext

The transition from Research to Industrialization

A notable theme at this year’s fair was the growing emphasis on productivity and the industrialisation of additive manufacturing (AM). As the industry matures, the focus is shifting from research-driven innovation to optimising manufacturing processes for greater efficiency, particularly in sectors such as aerospace, automotive, and energy. While there are still new systems and machines being launched, much of the spotlight was on solutions that integrate AM into mature manufacturing ecosystems, showcasing industrial use cases and best practices.

This year’s exhibits also highlighted the diversity of AM applications, spanning consumer and industrial markets. In one of the four exhibition halls, plastic printing took centre stage, with numerous exhibitors displaying 3D printers catering to hobbyists and small-scale users. Products ranged from colourful toys to personalised consumer items. At the same time, industrial-scale offerings demonstrated automation solutions for full production systems, reflecting the evolving role of AM as a core component of modern manufacturing.

Fewer Exhibitors, but Continued Innovation

Compared to 2023, the 2024 fair saw a slightly reduced number of exhibitors and a more spacious layout. Though there were fewer machines on display and fewer live demonstrations, the quality and variety of what was showcased remained impressive. While large-scale printed components were again prominent, this year saw an interesting shift with even more components being printed in copper. 

Certain technologies, such as Powder Bed Fusion-Laser Beam (PBF-LB), have passed critical turning points in their development. Rather than focusing on launching several new versions of machines with incremental capabilities, market players are now prioritizing advancements in productivity, materials, multimaterial solutions, industrial use cases, and collaborative efforts between material providers, machine manufacturers, and end-users of AM parts. 

In the past, many new ideas were introduced at Formnext, but not all continued due to market dynamics. Hybrid LPBF-subtractive manufacturing, for instance, gained attention five years ago but did not succeed. While the number of niche providers, such as small companies offering software tools or data-driven solutions, appears to be decreasing, this reflects a broader trend toward industrialization and technological maturity. This shift does not necessarily imply a lack of innovation or development but rather a strategic use of the Formnext platform to showcase the next steps in integrating additive manufacturing into industrial ecosystems. 

Emerging Material solutions

This year, the focus on new materials was more pronounced, especially with copper and copper alloys, which are valued for their superior electrical and thermal conductivity. Biobased plastics also made a strong showing, representing a significant step towards more sustainable manufacturing practices. These eco-friendly materials offer viable alternatives to traditional plastics, suitable for both small and large-scale applications.

One of the most notable trends was the emphasis on multimaterial solutions, spanning conventional PBF and Directed Energy Deposition (DED) technologies as well as cold spray and cladding techniques. These solutions enable the creation of complex, highly functional components by combining diverse material properties – such as magnetic and non-magnetic characteristics – or delivering enhanced wear resistance, corrosion protection, and different conduction properties.

Post-Processing: Gaining Momentum

Post-processing has become a key focus area as the industry seeks to meet service requirements for complex AM parts. More exhibitors were presenting solutions for depowdering, and surface finishing. Methods such as electrochemical techniques for surface treatment also caught attention, signalling the industry's push towards optimising every stage of the AM process.

The Global Supply Chain: Where’s the Buzz?

From a supply chain perspective, there was a sense of stagnation in market development. While there’s hope for a radical increase in AM’s adoption, it hasn’t yet materialised. Many machine suppliers are restructuring their offerings and consolidating their portfolios in an attempt to maintain profitability. The powder market, in particular, is seen as over-saturated, with concerns about long-term profitability in a market that is yet to reach the anticipated production volumes. 

Sustainability: A Vital Dialogue

Even though sustainability was not specifically highlighted at Formnext, there were many solutions targeting first-time-right manufacturing and remanufacturing, reflecting global net-zero goals. The push for sustainable manufacturing solutions such as reduced waste, lightweight construction, energy-efficient systems, and recyclable materials was evident across the industry. This trend aligns with our ongoing projects at RISE and underscores a promising synergy between our goals and global efforts.

Challenges and Opportunities for AM

Looking ahead, there is still uncertainty about when AM will take off within the global supply chain. While many suppliers remain optimistic, the growth has been slow and the industry is still far from reaching its full potential. 

There is still an increasing need for industrial-oriented development, particularly in metal AM. A challenge, slightly overlooked at this year’s Formnext, is the lack of robust monitoring systems for quality assurance in additive manufacturing. While many exhibitors showcased monitoring hardware, few demonstrated how these tools effectively ensure consistent product quality. The focus remained on machine capabilities – speed, size, and production efficiency – rather than on material qualification, metallography, or non-destructive testing (NDT).

Effective monitoring tools are essential for process optimisation, repeatability, and ensuring material and product performance during production. Without them, AM processes risk variability in material properties, dimensional accuracy, and surface quality, leading to defects like warping or weak bonding. Addressing these gaps is critical for advancing AM technologies and achieving reliable, scalable production.

Despite this, the fair underscored that AM is progressing toward a mature, scalable, and sustainable manufacturing solution, with exciting opportunities for collaboration and innovation across the industry.

By understanding the growing demand for new material solutions, post-processing technologies, and enhanced productivity, alongside the growing need for competence development, component qualification and process monitoring, the Application Center for Additive Manufacturing can adapt its solutions to better support the Swedish manufacturing industry in its transition. These insights will also drive our efforts to accelerate the adoption and integration of AM across all sectors. 

Photo Source, main picture: Mesago Messe Frankfurt GmbH / Mathias Kutt
Photo Source, additional pictures: RISE