Each year Formnext provides a clear sense of where the AM industry is heading. It's a moment when machine makers, service providers, and industrial operators gather in one place. For companies exploring how to deploy AM in their operations, it is one of the best opportunities to see how AM is evolving and what direction the global ecosystem is taking.
This article reflects the combined observations of our team in attendance. Their insights come from the stands they visited, the discussions they held with industry partners, and the technical sessions and panels they joined throughout the event.
Across the event, it was clear that many companies are working with parts that meet demanding requirements (class parts). Yet few of these parts were shown on stands. Several exhibitors mentioned that qualified applications exist in aerospace, defense, and parts of energy, but they appear publicly in just a few niche events.
This means that the most meaningful progress in AM is often not the work you see in an exhibition booth. It is the work companies guard closely because the value sits in their design knowledge and qualification pathways.
This creates an interesting contrast. The industry is advancing in real ways, yet the advancements that matter most are not always the ones on display. It leads to the question: If the most advanced applications are not the ones we see, what is the best way to understand the real state of industrial AM?
One of the most striking things our team noticed was the combination of industrial systems and hobbyist printers within the same halls. Highly engineered metal systems stood only a few steps away from creative makers, model printers, and consumer-grade equipment.
The observation is that the two audiences have very different expectations and placing them together can send mixed signals about what AM represents. For industrial sectors that rely on qualification, traceability, and documented processes, this kind of layout can blur the picture. It reinforces the long-standing perception that AM is still associated with experimentation and play rather than with production and work.
It also creates questions about whether separating industrial AM from consumer and creative AM could help visitors better understand the maturity of each group. Industrial AM is a serious and complex manufacturing discipline. The show format sometimes makes this harder to see.
Across four halls, maritime applications were difficult to find. There were a few examples of propellers and the occasional classification society presence, but very little in the way of dedicated maritime content. Machine OEMs had representatives for aerospace, automotive, and general energy. None had business development specialists focused on maritime.
This does not mean the maritime sector is behind. The reasons are more straightforward. Maritime, as a global segment, is newer to AM adoption compared to aerospace, medical etc. And much of its AM activity is tied to private, NDA-protected RnD work between OEMs and operators. We also saw from end-user presentations that large asset operators are actively working on AM adoption and conducting RnD projects to integrate AM into their maintenance strategies. The demand exists. It is practical and growing.
The absence of maritime at the exhibition simply shows that there is still space for specialized partners. As fleets age and spare-parts challenges increase, we predict that maritime will likely feature more strongly at Formnext in the years ahead.
One of the clearest patterns from technical talks and discussions was the central role OEMs play in successful AM adoption. One energy industry end user presentation highlighted this well. Their team explored AM for a component in the late phase of a turbine’s operational life. They faced limitations with missing drawings, high LPBF cost, insurance and liability questions, and qualification needs. Using Binder Jetting reduces the cost, but the OEM later reentered the conversation and offered a conventional manufacturing of the part at a competitive price. This led to the AM route stopping there.
The lesson was not that AM is unsuitable. The lesson was that end users face natural structural barriers when trying to adopt AM independently. IP, qualification, and responsibility for part integrity all sit with the OEM. End users want faster lead times, and AM can deliver that, but the pathway works best when the OEM leads the process.
We saw a clearer understanding that AM succeeds when the OEM is involved. End users may look to AM for faster access to parts, but only the OEM can confirm suitability and ensure safe, qualified outcomes. Collaboration from the start is essential.
Printing was not described as the main bottleneck by anyone we spoke with. Qualification was. Companies shared similar concerns. High testing requirements. Cost of first article cycles. The need to build internal confidence before accepting a standard. And the tendency to select the most conservative classification level even when lower levels may be valid and more cost effective.
Standards bodies presented their own updates. The B205 standard from DNV is a good example. It outlines a structured way to manage digital inventory workflows and reduce lead time by completing preparation work in advance. This aligns strongly with what we see across industries. Digital preparation is reducing friction in qualification. It is not eliminating the cost, but it gives OEMs more predictability and control.
Qualification is the area that will shape AM adoption for the next several years. It is where the highest cost sits in many cases.
Digital inventory was referenced in several sessions and in the new guidance being developed by classification societies. Digital inventory is a way to bring structure, traceability, and readiness to part production workflows. It shortens lead time by completing data preparation before a manufacturing decision is made. It supports distributed production models. And it gives OEMs confidence that their parts can be produced under controlled conditions at qualified facilities.
Digital inventory is no longer viewed as an innovative idea. It is increasingly seen as a necessary component of how AM fits into industrial supply chains.
Across the halls we heard service bureaus looking for stronger, long-term partnerships and system manufacturers seeking strategic collaborators. Raw material suppliers, particularly from Asia, are expanding their presence, and OEMs are increasingly exploring partnership models that complement inhouse development as part of their "Make or Buy" decisions.
Analysts also pointed to ongoing consolidation, especially in the polymer sector. Metals appear to be following a similar pattern. This is a sign of a maturing ecosystem adjusting to real market needs and building more stable value chains.
Compared with previous years, Formnext 2025 had less emphasis on dramatic breakthroughs and more on practical use cases, incremental improvements. The industry is increasingly treating AM as a manufacturing method rather than a novelty. This shift will benefit sectors that manage long-life assets and need predictable, repeatable processes.
AM is becoming a complementary tool that fits specific problems where it creates real value. The next chapter of adoption will be shaped by thoughtful selection of parts, clear qualification pathways, and strong partnerships that connect engineering needs with reliable production networks.
Insights | 1 December 2025