The year 2020 marked a pivotal chapter in additive manufacturing, characterized by groundbreaking launches, transformative applications, and a global pandemic that tested the agility of the industry. Early in the year, tributes were paid to Dr. Carl Deckard, inventor of Selective Laser Sintering, whose pioneering work shaped decades of innovation. Colleagues described him as “a creative genius with so much more to contribute,” underscoring the enduring influence of his contributions.
At TCT Japan 2020, exhibitors showcased the latent potential of additive manufacturing as a future industrial powerhouse. Materialise Japan’s Managing Director, the company’s 12th employee, reflected on programming early Magics software and the vision of CEO Fried Vancraen, offering rare insight into Japan’s adoption of AM technologies.
Applications spanned diverse sectors. Ford introduced a novel approach to security by using a driver’s voice to generate unique 3D printed wheel locks. Porsche unveiled a bucket seat concept integrating additive manufacturing for improved ergonomics. Westinghouse Electric Company successfully installed a metal 3D printed fuel component at an Exelon nuclear plant, highlighting AM’s role in critical energy infrastructure. Honeywell achieved FAA certification for its first 3D printed flight-critical engine part, signaling aerospace’s deepening trust in the technology.
The COVID-19 pandemic accelerated AM’s role in emergency manufacturing. Carbon’s Digital Light Synthesis machines were deployed to produce PPE, while Photocentric’s print farm scaled to 350,000 face shields per week. These efforts demonstrated how distributed manufacturing could bypass traditional supply chain bottlenecks.
Generative design emerged as a key enabler of lightweight engineering. ParaMatters software was used to optimize Arcimoto electric vehicle parts, while Briggs Automotive Company re-engineered a supercar using AM and generative design principles. In sports, CCM Hockey collaborated with Carbon to deliver the first NHL-certified 3D printed helmet liner, merging performance with safety.
Industry developments reshaped the competitive landscape. Vyomesh Joshi announced his retirement as CEO of 3D Systems, later succeeded by Jeff Graves. Stratasys pursued a leaner operating model, reducing staff by 10%, and acquired Origin in a deal valued up to $100 million. Covestro’s €1.61 billion acquisition of DSM’s 3D printing business expanded its materials portfolio. Desktop Metal went public via a reverse merger with Trine Acquisition Corp, valuing the company at $2.5 billion.
Hardware innovation continued despite global disruptions. VELO3D introduced the Sapphire XC, a large-format metal AM system with a 600 x 550 mm build volume and eight 1KW lasers. SLM Solutions announced the NXG XII 600, targeting high-volume metal part production. MakerBot expanded its Method line with carbon fiber-capable printers aimed at professional users. BMW Group opened a €15 million Additive Manufacturing Campus to industrialize 3D printing.
Aerospace remained a fertile ground for AM maturity. Stratasys VP of Aerospace Scott Sevcik stated, “Aerospace is the right place for additive manufacturing to mature,” citing rigorous certification processes and the sector’s demand for lightweight, high-performance components. BAE Systems revealed plans to produce 30% of Tempest aircraft components additively within its new smart factory. Boom Supersonic’s XB-1 demonstrator incorporated 21 flight components produced with VELO3D’s metal printing technology.
Materials advances also played a critical role. BASF launched a 17-4 PH stainless steel filament for FFF printing, while Materialise introduced Bluesint, enabling parts to be printed with 100% reused powder. HP expanded its Metal Jet applications, with COBRA Golf and the US Marine Corps adopting the technology, and unveiled a BASF-developed polypropylene material.
The year closed with reflections from industry veterans. Stratasys founder Scott Crump, retiring after more than 30 years, recounted the journey from inventing Fused Deposition Modelling to navigating the hype cycles of acquisitions like MakerBot. His legacy, alongside the rapid advancements of 2020, underscored a year where additive manufacturing not only adapted to unprecedented challenges but also cemented its role in shaping the future of aerospace, automotive, energy, and beyond.