Rethinking Quality: Why Additive Manufacturing Must Grow Up to Move Forward
This lack of focus on quality has become the single biggest obstacle to the broader adoption of AM for end-use parts.
By Felix Manley, Sasha Bruml
For years, additive manufacturing (AM) has been synonymous with prototyping. Fast, flexible, and relatively affordable, it allowed engineers and designers to bring ideas to life quickly. Expectations around the technology set are continuing to grow as AM processes edge further and further into the realm of production. It is here that the AM industry faces a challenge that it can no longer afford to ignore. Quality.
The AM sector, particularly in the subcontract bureau space, still places too much emphasis on cost and delivery times. Those metrics may work for one-off parts or early-stage concepts, but they fall short when AM is used to produce real, functional components at volume. In this environment, quality shouldn’t be seen as a value-add, but as the baseline.
From our perspective at a leading AM subcontract bureau, this lack of focus on quality has become the single biggest obstacle to the broader adoption of AM for end-use parts. And while the AM ecosystem (including software, hardware, and materials) has evolved rapidly in recent years, many of the expectations around it have not.
REDEFINING QUALITY IN ADDITIVE MANUFACTURING
Ask 100 people to define quality in manufacturing, and you’ll get 100 different answers. But in the context of AM for production, quality must mean more than just mechanical strength or material spec. It must include repeatability across production batches, surface finish that meets application needs, version control that ensures the right part gets made every time, and confidence that parts will perform reliably under real-world conditions.
This is where AM still struggles to compete with traditional processes like injection molding. Molded parts benefit from decades of development, rigorous quality systems, and highly predictable outcomes. AM, by comparison, is often treated as a flexible but inconsistent tool.
Too many bureaus still operate like print shops, taking what comes in, slicing it, printing it, and shipping it out. There’s minimal dialogue about how the part will be used, whether it’s been designed for the process, or whether it will actually meet the customer’s functional requirements.
And that’s a problem.
THE PROBLEM WITH "PRINT AND SHIP"
This print-and-ship mentality not only undermines the value of AM but also erodes customer trust. A part may arrive quickly and cheaply, but if it doesn’t perform as expected (due to poor surface finish, incorrect programming, or unconsidered material choice) then speed and cost savings are irrelevant. Worse still, it damages the perception of AM as a credible production method. As evangelists for the broader uptake of AM across industry due to its innovative possibilities and support of sustainability initiatives, this concerns us deeply.
For us, the experience has been clear. Companies are interested in using AM for production, but they often lack the technical confidence to fully commit. And who can blame them? Inconsistent results and vague quality standards have made it hard to trust.
What’s often missing is a real conversation about quality at the outset. Not just “how fast can you print this,” but “will this part work, last, and look the way it needs to?” In our experience, the more questions asked before printing begins, the better the results in the end.
DESIGNING FOR AM IS THE MISSING LINK
One of the most overlooked contributors to quality in AM is the design stage itself. While AM has fewer design constraints than traditional processes, it’s also where many of the downstream problems begin. Designing parts without considering part orientation, the restriction on geometry types that cause warping, or using CNC tolerances can all introduce quality issues that no post-processing step can fix.
Because of this, subcontract AM bureaus should offer free technical consultation to every customer before production begins. It is not always needed, and plugging into a well-designed automated system, especially for established part batch runs, can offer genuine time-saving advantages. But where it is beneficial, the aim is simple, essentially to validate the design for the manufacturing method so that the part not only prints correctly but performs exactly as intended. This hands-on, consultative approach is a far cry from the anonymous upload-and-print model that dominates the bureau landscape.
There’s a difference between being a print service and being a manufacturing partner. We choose the latter, because we believe customers deserve more than just parts, they deserve optimized outcomes.
SURFACE FINISH
Another area where quality is often misunderstood is surface finish. It’s easy to dismiss it as aesthetic, but in reality, it affects everything from mechanical properties, porosity, and surface cleanliness to wear resistance, fluid dynamics, and user perception. In applications where parts are visible, handled, or fitted alongside other components, surface finish is a performance factor.
That’s why we have invested heavily in in-house post-processing, including vapor smoothing, shot peening, vibro finishing, and color dyeing, to ensure parts don’t just meet expectations but exceed them. Finishing should never be an after-thought, it’s a vital part of the quality equation.
Too often parts delivered to customers from 3D printing bureaus look unfinished, and that’s because they are. If we expect AM to compete with traditional production, it must deliver a complete part, not just a printed object.
THE EXPERIENCE GAP
Another real barrier to quality in AM is the knowledge gap that still exists across the industry. Many companies want to explore AM for production but don’t yet have the experience or technical know-how to navigate it successfully. That’s understandable as this is still an emerging field with a steep learning curve.
We see this as an opportunity, not a frustration. By supporting customers with design feedback, technical guidance, and open conversations about what will and won’t work, we’re helping to close that gap. That’s good for customers and good for the industry.
We’ve found that the more collaborative the process, the better the result. That’s how trust is built, not just in our services, but in the potential of additive manufacturing itself.
THE CALL FOR INDUSTRY-WIDE CHANGE
It’s time for subcontract AM bureaus to stop acting like print shops and start acting like manufacturers. That means adopting rigorous quality standards, engaging in dialogue with customers, and taking responsibility for the outcomes of every part they deliver.
If the AM industry wants to be seen as a serious alternative to traditional production methods, it must do more than deliver parts on time and on budget. It must deliver parts that perform. That’s what customers expect from injection molders, CNC machinists, and metal fabricators. AM should be no different.
There are encouraging signs. More companies are demanding traceability, process control, and material data. Surface finish expectations are rising. And forward-thinking bureaus are beginning to invest in metrology, validation, and DfAM feedback. But the shift is not happening fast enough.
A SHARED OBSESSION WITH QUALITY
Our goal isn’t just to print parts, but to help customers succeed with AM and help to turn the potential of additive manufacturing into real-world innovation. That means working collaboratively, sharing knowledge, and never compromising on quality for the sake of a faster lead time or a cheaper quote.
We believe that quality is a shared responsibility. It starts with asking better questions, designing with purpose, and choosing the right materials and processes. It ends with parts that don’t just function, but perform, consistently, reliably, and beautifully.
Unless quality becomes the obsession, AM will continue to live in the shadow of traditional manufacturing. It will be seen as novel, not essential. And it will fall short of its true potential.
The technology is ready. The materials are ready. The demand is there. But the mindset around quality needs to catch up.
It’s time to grow up. And it starts with putting quality first.
