Additive manufacturing (AM) has emerged from its early identity as a prototyping tool to become a production-ready technology across multiple industrial sectors. Driven by advances in material science, machine precision, and digital workflows, AM is now functionally embedded in diverse phases of the manufacturing value chain. According to Jabil’s 2023 industry survey of 200 senior decision-makers, 97% of organizations use AM for prototyping, but 67% now also apply it to fabricate production-grade parts. Applications in jigs, fixtures, tooling (58%), bridge production (59%), and maintenance (53%) demonstrate that AM’s role extends far beyond concept validation.
This white paper explores how AM is being operationalized in industrial contexts—from its growing application across the product lifecycle to its function-specific integration in aerospace, healthcare, automotive, and high-mix manufacturing. It also examines the organizational readiness factors that enable scalable deployment, with insights into how leadership perception and infrastructure investment impact functional use cases.
The journey from prototype to production is no longer aspirational—it is operational. To succeed, manufacturers must strategically align design engineering, process control, and digital integration, supported by experienced partners such as RapidMade who can deliver turnkey additive solutions at scale.
Introduction: Additive Manufacturing in Industrial Evolution
Historical Foundations and Maturity Curve
Additive manufacturing originated in the 1980s as a means to rapidly generate physical models from digital data. The earliest commercial use cases focused on speeding up the design process through visual and functional prototyping. Over the decades, AM technologies such as fused deposition modeling (FDM), selective laser sintering (SLS), and direct metal laser sintering (DMLS) evolved to meet increasingly rigorous demands for mechanical integrity, thermal performance, and geometric complexity.
Today, AM supports a broader industrial ecosystem. It enables design-for-manufacture without tooling, lightweighting for aerospace components, rapid customization for orthotics and dental guides, and real-time replacement of aging parts in the field. The shift from prototyping to production is driven by technological convergence: material advancements, expanded build volumes, higher process repeatability, and digital integration with engineering workflows.
Scope of the 2023 Industry Survey
The 2023 Jabil survey aggregates data from 200 senior AM decision-makers across engineering, R&D, production, and operations roles. A notable 65% of participants come from companies with annual revenues exceeding $5 billion, indicating a highly industrialized respondent base. The survey provides insights into real-world implementation of AM, spanning aerospace, automotive, electronics, heavy equipment, and healthcare sectors.
This paper focuses on analyzing how these companies are functionally deploying AM throughout the product lifecycle—and what this means for strategic scaling.
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Functional Integration of Additive Manufacturing
Primary Applications Across Manufacturing Functions
The survey reveals that AM is no longer confined to design labs. Its applications span early-stage development to post-sale maintenance. Functional integration patterns include:
- Prototyping (97%): Enables rapid iteration and form/function testing with minimal lead times.
- End-Use Production Parts (67%): Used for low-to-mid volume runs where tooling costs are prohibitive or agility is required.
- Bridge Production (59%): Fills the gap between prototype approval and full-volume manufacturing, allowing faster product introduction.
- Tooling, Jigs, and Fixtures (58%): Supports production lines with rapid, custom solutions that reduce operator fatigue and error rates.
- Repair and Maintenance (53%): Enables on-demand fabrication of obsolete or unique parts, especially in distributed field operations.
- R&D Applications: Supports material and structural testing in early development programs.
These findings indicate that AM serves not only as a validation tool, but as an operational asset embedded within manufacturing ecosystems.
Lifecycle Integration
AM’s impact spans the product lifecycle. Surveyed organizations identified the greatest benefits in:
- Prototyping (96%)
- Design (52%)
- Small-scale production (27%)
These applications support faster innovation cycles and minimize delays during design freeze, tooling, or initial market launch. As use cases expand into final part production and repair, AM contributes to cost savings, agility, and reduced downtime.
Sector-Specific Functional Use
- Aerospace and Defense: AM is used for certified lightweight metal brackets, wire-routing systems, and ducting. The ability to consolidate parts and eliminate fasteners reduces weight and improves performance.
- Healthcare and Orthopedics: Surgeons use custom 3D-printed guides and implants tailored to patient-specific anatomy, reducing surgical time and improving outcomes.
- Automotive: OEMs deploy AM for under-hood components, interior fixtures, and assembly tools, especially for short-run models or specialty packages.
- Heavy Industry and Transportation: MRO operations benefit from AM’s ability to fabricate discontinued parts or develop rugged tooling for field conditions.
These examples highlight how AM supports both customization and consistency—delivering performance benefits across design and operations.
Scaling Through Infrastructure and Volume
A common misconception is that more printers equal greater capability. However, the survey finds that application diversity, not volume alone, distinguishes AM maturity. Firms with more than 100 in-house 3D printers are more likely to:
- Engage in component repair (43%)
- Produce jigs and fixtures internally (71%)
- Use AM across multiple departments beyond engineering
These organizations demonstrate that functional scaling requires more than hardware—it requires process discipline, workforce expertise, and cross-functional alignment.
Strategic Leadership Perspectives and Organizational Readiness
C-Suite Alignment with AM Integration
The strategic outlook on AM is becoming increasingly clear. In 2023:
- 55% of executives view AM as a strategic capability
- 40% recognize it as an alternative production method
- Only 5% see it as non-essential at present
This level of executive endorsement signals growing confidence in AM’s value proposition. Compared to 2021, when only 37% considered AM strategic, this reflects an 18-point increase and aligns with the technology’s rising operational impact.
Infrastructure Investment and Organizational Maturity
Organizational readiness is strongly correlated with infrastructure and leadership buy-in. Companies that have:
- 100 in-house printers
- Dedicated AM teams
- Internal material testing and design-for-additive processes
…are more likely to treat AM as a production resource rather than a prototyping accessory. These firms also expect AM to provide rapid response capabilities during production disruptions, reduce tooling costs, and enable distributed manufacturing models.
By contrast, firms with fewer than 10 printers or without centralized AM strategy tend to confine usage to prototyping. This underutilization results in missed opportunities for cycle-time reduction, cost control, and differentiated product development.
Conclusion and Recommendations
Additive manufacturing is no longer speculative—it is operational and industrialized. As companies seek to optimize product development cycles, reduce lead times, and improve agility, AM presents a compelling solution that bridges design and manufacturing.
The 2023 Jabil survey illustrates that functional integration is both broad and deep:
- Prototyping remains foundational but no longer defines AM’s boundaries.
- Production, tooling, and maintenance are now routine applications.
- C-suite recognition and infrastructure investment are prerequisites for strategic deployment.
To transition successfully from prototyping to production, organizations must treat AM as an enterprise capability. This includes investing in design expertise, certified materials, and system interoperability. Most critically, companies must work with partners who can translate AM’s potential into operational success.
Partnering for Industrial Additive Success
RapidMade provides full-service additive manufacturing support, helping clients navigate the transition from design iteration to production-grade fabrication. With expertise in design for AM (DfAM), certified material access, and scalable production systems, RapidMade delivers rapid, reliable, and cost-effective 3D printing solutions.
Visit rapidmade.com to schedule a consultation and discover how our 3D printing services can support your shift from prototype to production.
