The Evolution of Metal Parts Manufacturing: A Factory Floor Perspective

Metal parts manufacturing has come a long way over the years. What started with manual casting and forging has now advanced to CNC machining and even 3D printing. These changes have completely transformed the way metal parts are designed, made, and delivered on the factory floor, bringing in much more speed and flexibility to production.

In today’s competitive world, manufacturers need to ensure quick turnaround times, use materials wisely, and maintain safe production processes to keep up with customer demands and stay ahead of the competition. That’s why it’s so important for engineers, managers, and decision-makers to keep up with these advancements and understand how technologies like metal 3D printing are shaping the future of manufacturing.

Even with all the rapid technological progress, manufacturing still faces its fair share of challenges. Companies are under constant pressure to get products to market faster, but traditional tooling methods often slow things down. Creating custom tools for small production runs can be expensive, and ensuring quality when using new technologies often means updating existing standards and processes.

Metal additive manufacturing, or metal 3D printing, is helping tackle many of these issues. It allows for faster production cycles, lets manufacturers create complex parts without needing costly tooling, and offers the flexibility to tweak designs during development. Plus, metal 3D printed parts are now meeting strict validation and certification standards in industries like automotive, aerospace, and medical, proving that 3D printing is not just for prototypes anymore — it’s becoming a reliable production method.

In this article, we’ll look at how metal parts manufacturing has evolved over time and where it’s headed next, focusing on practical ways engineers and production teams can improve their workflows, remove bottlenecks, and create more value using metal 3D printing.

Metal Parts Manufacturing: Traditional Methods vs. Modern Techniques

Traditional Metalworking

For decades, processes like casting, forging, machining, and stamping have been the backbone of metal parts manufacturing. While they’re reliable, they come with some clear drawbacks:

• Long lead times due to tooling and setup
• High upfront costs
• Significant material waste, which affects both budgets and sustainability goals
• Limited flexibility when quick design changes are needed
• Skilled labor shortages, as these methods often rely on experienced workers whose skills are becoming harder to replace

Modern Manufacturing Technologies

Today, manufacturers use advanced methods like CNC machining and 3D printing (additive manufacturing), which offer:

• Greater precision and consistency
• The ability to change designs quickly and easily
• Less waste and shorter lead times

Although these modern solutions clearly have benefits over traditional approaches, adopting technologies like metal 3D printing isn’t always easy. Companies need to address skill gaps, justify the initial investment, and manage the cultural changes that come with shifting how parts are designed and produced.

Overcoming Common Challenges in Adopting Metal 3D Printing

Modern manufacturing technologies, like metal 3D printing, bring clear benefits, but adopting them isn’t without challenges. By tackling these obstacles head-on, manufacturers can make the most of additive manufacturing and integrate it smoothly into their workflows.

Knowledge and Skills Gap

Many engineers and technicians aren’t yet trained in design for additive manufacturing (DfAM), which is essential for using 3D printing effectively. This gap can be closed through focused training programs. Partnering with experienced 3D printing companies, like Markforged, also helps, as they often provide training, certifications, and expert support to upskill teams quickly.

Initial Investment

Setting up metal 3D printing requires upfront costs, which can be a hurdle for some manufacturers. One way to manage this is to start small with hybrid systems, such as the FX10, that combine composite and metal printing. These scalable solutions let companies achieve quick wins and gradually build their capabilities, making it easier to justify further investment down the line.

Change Management

Bringing in any new technology comes with cultural resistance. To overcome this, it’s important to involve production teams early in the process. Starting with small pilot projects, like printing factory tools or low-volume parts, helps showcase the practical benefits of 3D printing, making the transition smoother for everyone involved.

Validation and Certification

Meeting strict quality standards is a must, especially in regulated industries. For example, Azoth 3D managed to pass General Motors’ rigorous Production Part Approval Process (PPAP) to produce a polished stainless steel medallion for the manual shifter knob in a Cadillac — the first metal 3D printed production part in the brand’s lineup. Their success shows that, with proper validation and early collaboration with quality teams, metal 3D printing can meet the same high standards as traditional machining or casting.

Current Trends in Metal Parts Manufacturing

Adopting metal 3D printing is just the beginning. The real value comes from how new trends are changing what’s possible on the factory floor. Smarter factories, better materials, and the growing need for customization are no longer future ideas — they’re creating real advantages for companies ready to adapt.

Smart Factories & Automation

Robotics, automation, and connected systems (Industry 4.0) have become essential. Companies in sectors like automotive and defense are combining automation with metal 3D printing to produce high-quality parts at scale efficiently.

Advanced Materials

New metal powders and composites are expanding what can be achieved with 3D printing. For example, PTI Tech uses metal binder jetting with materials like 316L stainless steel to create critical parts, showing how advanced materials are bridging the gap between prototypes and full production.

Low-Volume, High-Mix Production

The demand for custom, small-batch production is rising fast. Dixie Iron Works has taken advantage of this by 3D printing custom metal parts on demand. This approach frees up their CNC machines for other jobs and cuts down on excess inventory costs.

Sustainability Pressures

Sustainability is now a top priority. Additive manufacturing creates far less waste compared to traditional subtractive methods. Companies like Dixie Iron Works and Toivalan Metalli are adopting digital inventories, which help reduce material use, cut shipping emissions, and speed up response times.

The Benefits of 3D Printing Metal Parts

Metal 3D printing isn’t about completely replacing traditional methods. It’s about adding new possibilities and efficiencies throughout production:

• Faster timelines – Reduce development cycles from weeks to days
• Lower costs – Eliminate the need for tooling and reduce material waste
• More design freedom – Easily print complex shapes and consolidate parts into single components
• Production-ready strength – Create durable, high-performance parts
• Safer operations – Some methods, like the FX10’s flexible metal filament, are safe to handle without gloves or respirators

For example, Dixie`` Iron Works used Markforged’s Metal X printer to remove costly CNC setups for small production runs. They redesigned assemblies into single parts, cut material waste by 75%, and significantly lowered production costs.

PTI Tech also saw major benefits by using metal binder jetting to prototype stainless steel elevator components. They reduced their product development time from 16 weeks to just four, skipped expensive pre-production tooling, and delivered durable, production-quality parts.

Platforms like the PX100 take these benefits even further by enabling true high-volume production with binder jetting. Combined with the FX10, which offers safe, flexible filament-based metal printing directly on the factory floor, Markforged’s technology is making additive manufacturing more accessible and scalable than ever before.

Tackling Common Concerns

While there have been concerns about the strength and durability of 3D-printed metal parts, companies like Dixie Iron Works and Azoth have proven these worries wrong. Azoth even passed strict certification processes to meet Tier 1 automotive quality standards.

Safety has also been a challenge in traditional metal 3D printing, as powder-based methods require handling hazardous materials. The Markforged FX10 solves this by using flexible metal filaments that are safe to handle without special protective gear. This innovation lowers operational risks and makes it easier to integrate metal 3D printing onto the factory floor.

Looking Ahead: The Future of Metal Parts Manufacturing

Manufacturing is moving towards being faster, more flexible, and more sustainable. Metal 3D printing solutions like the FX10 and PX100 are leading this change, offering safer operations, lower costs, and quicker lead times. By adopting proven 3D printing technologies, manufacturers can stay agile and competitive in today’s demanding market.

Innovation is already here, supported by real success stories. Now is the time to bring these advancements to the factory floor and build a smarter, more efficient future for metal parts manufacturing.