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7 Types of Additive Manufacturing Used in Smart Factory Settings
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From analog to digital, additive manufacturing (AM) is transforming how manufacturers operate in smart factory environments. Guided by computer-aided design (CAD) software or 3D scanning, AM builds functional objects layer by layer with high precision, repeatability, and material efficiency. While often grouped under the broad label of “3D printing,” smart factories do not rely on a single method. Instead, they deploy multiple additive manufacturing technologies and additive manufacturing processes, each optimized for specific materials, energy sources, and levels of automation.
7 Types of Additive Manufacturing Used in Smart Factories
Source: The Manufacturing Report
In contrast to traditional subtractive manufacturing, which cuts or mills material from a solid block, AM builds objects using a layer-by-layer approach. Smart factories commonly adopt seven types of additive manufacturing, each capable of integration with automated production lines:
1. Material Jetting: Like inkjet printing, material jetting deposits liquid photopolymer droplets, curing them with UV light. Its precision and repeatability make it ideal for smart factory workflows that require high-resolution parts, tight tolerances, and minimal human intervention, particularly in automated quality-controlled environments.
2. Vat Photopolymerization: Using photopolymer resin and ultraviolet light, vat photopolymerization creates objects through a controlled chemical reaction. Subtypes include Stereolithography (SLA), Digital Light Processing (DLP), and Continuous Digital Light Processing (CDLP). Vat Photopolymerization is well suited for smart factories producing complex geometries at scale, thanks to consistent output and automation-friendly post-processing.
2. Vat Photopolymerization: Using photopolymer resin and ultraviolet light, vat photopolymerization creates objects through a controlled chemical reaction. Subtypes include Stereolithography (SLA), Digital Light Processing (DLP), and Continuous Digital Light Processing (CDLP). Vat Photopolymerization is well suited for smart factories producing complex geometries at scale, thanks to consistent output and automation-friendly post-processing.
3. Binder Jetting: Binder jetting fuses powdered materials with liquid binding agents, one layer at a time, to form parts. Often used for metals or ceramics, Binder Jetting fits naturally into smart factory environments where automated depowdering, sintering, and finishing systems are already in place, reducing manual handling and production variability.
4. Material Extrusion: Patented in the 1980s by S. Scott Crump, material extrusion feeds thermoplastic filament through a heated nozzle, depositing it layer by layer. Fused Deposition Modeling (FDM) is widely used in smart factory prototyping and small-batch production, offering a cost-effective additive manufacturing type that integrates easily with automated design iteration and digital inventory systems.
4. Material Extrusion: Patented in the 1980s by S. Scott Crump, material extrusion feeds thermoplastic filament through a heated nozzle, depositing it layer by layer. Fused Deposition Modeling (FDM) is widely used in smart factory prototyping and small-batch production, offering a cost-effective additive manufacturing type that integrates easily with automated design iteration and digital inventory systems.
5. Powder Bed Fusion: One of the earliest industrial AM techniques, Powder Bed Fusion melts powdered material using a laser or electron beam. Variations include selective laser melting (SLM) and laser sintering (LS), making this process ideal for automated smart factory environments requiring precision and scalability.
The BMW Group utilizes automated Powder Bed Fusion lines to produce thousands of aluminum water pump wheels. By integrating the automated Powder Bed Fusion lines into a "digital twin" environment, BMW has automated the entire workflow, from the initial laser melt to robotic arms removing the finished parts, minimizing manual intervention and maximizing scale.
Source: BMW Group
6. Sheet Lamination: Processes such as ultrasonic additive manufacturing, laminated object manufacturing, and selective deposition lamination stack sheets of material to create parts. Sheet lamination is often selected in smart factories for its speed, material efficiency, and compatibility with automated composite production, particularly for large-format or layered components.
7. Directed Energy Deposition: Similar to welding, Directed Energy Deposition (DED) uses a focused energy source to melt and fuse metal parts. This Directed Energy Deposition manufacturing process supports automated repair, reinforcement, and large-part fabrication, making it especially valuable in heavy-industry smart factories with robotic arms and IIoT monitoring systems.
7. Directed Energy Deposition: Similar to welding, Directed Energy Deposition (DED) uses a focused energy source to melt and fuse metal parts. This Directed Energy Deposition manufacturing process supports automated repair, reinforcement, and large-part fabrication, making it especially valuable in heavy-industry smart factories with robotic arms and IIoT monitoring systems.
Harnessing The Advantages of Additive Manufacturing
Globe Newswire predicts the global additive manufacturing market will surpass $34 billion by 2028. Smart factories use additive manufacturing processes to:
- Reduce supply chain complexity with on-demand production. For example, Siemens Mobility uses a "Digital Inventory" to 3D print replacement train parts when they are needed. The Digital Inventory system eliminates the need for massive physical warehouses and can reduce lead times for critical components from weeks to just days.
- Streamline production through automated workflows and robotics, moving parts efficiently between machines.
- Minimize material waste with precise layer-by-layer fabrication and recycling of unused materials.
- Lower prototyping costs with rapid iteration of designs.
- Integrate with IIoT systems for real-time monitoring and adaptive production.
From high-precision metal parts to intricate photopolymer resin components, additive manufacturing technologies enable smart factories to operate faster, more efficiently, and with greater flexibility.
Accelerate Smart Factory Innovation with Braemac Americas
Braemac Americas helps manufacturers implement additive manufacturing technologies that align with smart factory requirements. By offering a broad portfolio of components, connectivity solutions, and industrial-grade systems, Braemac Americas supports the infrastructure that allows multiple additive manufacturing types to operate reliably within automated production environments.
By leveraging Braemac Americas’ additive manufacturing systems, components, and solutions together, factories can operate with greater efficiency, reliability, and scalability. This enables faster prototyping, reduces waste, and delivers robust performance across diverse production applications.
u-blox MAYA-W2
The u-blox MAYA-W2 series are compact, low-power, host-based tri-radio modules for industrial IoT applications, supporting dual-band Wi-Fi 6 (up to 480 Mbit/s throughput), Bluetooth 5.4 including LE Audio, and 802.15.4 for Thread and Zigbee mesh networks. Designed for smart manufacturing, building automation, asset tracking, telematics, and EV charging infrastructure, the modules feature secure boot, secure OTP, and efficient coexistence management for reliable performance in dense wireless environments.
Available in variants with PCB antennas, U.FL connectors, and antenna pins, the MAYA-W2 modules support MU-MIMO, flexible channel widths (20/40/80 MHz), and multiple operating modes including access point, station, and P2P connections. Measuring 10.4 × 14.3 × 1.9 mm, these modules provide engineers with versatile, secure, and high-performance solutions for future-proof industrial IoT devices.
Digi International IX20
The Digi IX20 by Digi International is a rugged LTE router built for critical industrial, retail, and infrastructure applications. It offers flexible connectivity with dual Ethernet and serial ports, multi-carrier cellular redundancy via Digi SureLink®, and WAN aggregation with Digi WAN Bonding for reliable, always-on performance. FirstNet Capable™ models support primary responder communications, while built-in security features including Digi TrustFence®, stateful firewall, VPN, and FIPS 140-2 compliance protect devices and data. Centrally managed through Digi Remote Manager® as part of the Digi 360 solution, the IX20 enables easy deployment, mass configuration, and out-of-band management. With its compact, industrial-grade design and versatile feature set, it delivers secure, scalable, and resilient networking for large-scale IoT and industrial deployments.
Types of Additive Manufacturing Frequently Asked Questions
What is additive manufacturing (AM)?
Additive manufacturing (AM) is a process that builds objects in layers using digital designs, rather than removing material like traditional subtractive manufacturing. AM allows manufacturers to produce complex parts with precision, repeatability, and minimal waste.
Additive manufacturing (AM) is a process that builds objects in layers using digital designs, rather than removing material like traditional subtractive manufacturing. AM allows manufacturers to produce complex parts with precision, repeatability, and minimal waste.
What are the main types of additive manufacturing?
The main types of additive manufacturing include Material Jetting, Vat Photopolymerization, Binder Jetting, Material Extrusion, Powder Bed Fusion, Sheet Lamination, and Directed Energy Deposition. Each type of additive manufacturing is suited for different materials, energy sources, and levels of automation, helping manufacturers choose the optimal process for their production needs.
The main types of additive manufacturing include Material Jetting, Vat Photopolymerization, Binder Jetting, Material Extrusion, Powder Bed Fusion, Sheet Lamination, and Directed Energy Deposition. Each type of additive manufacturing is suited for different materials, energy sources, and levels of automation, helping manufacturers choose the optimal process for their production needs.
How does additive manufacturing differ from traditional manufacturing?
Additive manufacturing differs from traditional manufacturing because it builds objects in layers rather than removing material from a bulk object. This layer-based approach reduces waste, allows for complex geometries, and can integrate with automated production workflows.
Additive manufacturing differs from traditional manufacturing because it builds objects in layers rather than removing material from a bulk object. This layer-based approach reduces waste, allows for complex geometries, and can integrate with automated production workflows.
Why is additive manufacturing important for modern production?
Additive manufacturing is important for modern production because it enables efficient, flexible, and automated manufacturing, supports rapid prototyping, and reduces supply chain complexity. Manufacturers can produce parts faster, with higher accuracy, and scale operations more easily.
Additive manufacturing is important for modern production because it enables efficient, flexible, and automated manufacturing, supports rapid prototyping, and reduces supply chain complexity. Manufacturers can produce parts faster, with higher accuracy, and scale operations more easily.
What materials can be used in additive manufacturing?
Additive manufacturing can use a wide range of materials, including metal powders, thermoplastic filaments, and photopolymer resins. The choice of material depends on the type of additive manufacturing process and the desired properties of the final product.
Additive manufacturing can use a wide range of materials, including metal powders, thermoplastic filaments, and photopolymer resins. The choice of material depends on the type of additive manufacturing process and the desired properties of the final product.
How does additive manufacturing support automation?
Additive manufacturing supports automation by integrating with robotics, IIoT systems, and automated production lines. This allows factories to produce parts with minimal human intervention while maintaining consistent quality and efficiency.
Additive manufacturing supports automation by integrating with robotics, IIoT systems, and automated production lines. This allows factories to produce parts with minimal human intervention while maintaining consistent quality and efficiency.
How can Braemac Americas help with additive manufacturing?
Braemac Americas helps manufacturers implement high-performance additive manufacturing systems by providing components, materials, and solutions from best-in-class suppliers. With Braemac Americas’ offerings, production lines can operate with greater efficiency, reliability, and scalability, enabling faster prototyping, reduced waste, and robust performance across a wide range of applications.
Braemac Americas helps manufacturers implement high-performance additive manufacturing systems by providing components, materials, and solutions from best-in-class suppliers. With Braemac Americas’ offerings, production lines can operate with greater efficiency, reliability, and scalability, enabling faster prototyping, reduced waste, and robust performance across a wide range of applications.
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