For many businesses in customer fulfillment or consumer goods, maintaining smooth operations in today’s global climate has become increasingly challenging. In addition to the instability created by the Trump administration’s tariff policies, global supply chains – once efficient in reducing lead times and costs – are becoming increasingly vulnerable to disruptions. As a result, many companies are turning to emerging technologies to aid them in reshoring their production lines. Among these innovations, additive manufacturing has risen to the forefront, driven by growing demand for more efficient, customized, and sustainable production methods.
The Risks of Outdated Models
Since the start of the Covid-19 pandemic, manufacturers have faced ongoing challenges with part sourcing and transportation. Consider the following notable example: the 2021 blockage of the Suez Canal, a grounded container ship halted access through the canal for six days, stranding 369 ships and $9.6 billion in trade.
From unexpected events like this to economic instability and natural disasters, today’s complex supply chains have become increasingly fragile—leaving us less prepared to respond to disruptions.
While supply chain issues are not new, discussions around reshoring have gained urgency, especially as the threat of a trade war continues to loom between the U.S. and its neighbors, creating uncertainty for manufacturers dependent on foreign-made parts to sustain production. To survive the impending storm, companies must invest in technologies that allow them to bolster self-sufficiency and mitigate risks associated with foreign supply dependencies.
Solving Supply Chain Instability with Additive Manufacturing
Additive manufacturing, also referred to as 3D printing, is a newer form of manufacturing that generates parts by fusing stacked layers of material. It differs from the more traditional routes of subtractive or formative manufacturing by focusing on building up a part rather than cutting away from a block of material or utilizing a mold. As a result, additive manufacturing can often offer lower material and set-up costs, shortening lead time in the process.
Traditional supply chains typically struggle with issues like limited capacity to deliver minimum order quantities (MOQs), high inventory carrying costs, and long setup times for prototyping. Whether they produce their own parts or rely on external vendors, to reduce the impact of potential disruptions, operators are also forced to keep spare parts for machine repairs on hand. However, this requires significant storage space, which can come with a hefty price tag and logistical burdens.
While emerging technologies present their own challenges—mainly the upfront investment in equipment and training—they offer tremendous value by enabling more agile and self-sustaining manufacturing.
Additive manufacturing allows companies to bypass the headache of sourcing parts externally or building a large inventory by enabling the production of parts on-demand. It requires no additional tooling or set up to produce a new design; instead, end-use parts can be created in minutes, requiring little to no post-processing.
Dr. Mark Cotteleer, Research Director at Deloitte, notes that manufacturers using additive manufacturing have experienced significant productivity gains. “In consumer products—from shoes to motorcycles—we’ve seen time-to-market drop by as much as 90%, and prototype costs fall from nearly $2,500 to as low as $50 in certain applications.”
Additive manufacturing helps companies modernize by addressing the limitations of traditional methods. It enables localized production and rapid scaling, thus reducing reliance on complex supply chains. This allows companies to become more self-sustaining and resilient in the face of political and economic uncertainty.
“Additive manufacturing empowers companies to produce on demand, cut costs, and stay in control—no middlemen, no delays.”
– Mitch Debora, CEO Mosaic Manufacturing
Future-Proofing Operations
Companies that invest in innovative technologies position themselves to gain a competitive edge and maintain agility in an increasingly uncertain landscape. The integration of additive manufacturing into modern supply chains goes beyond adopting new technology—it represents a fundamental shift in operations to meet the demands of a rapidly evolving market.
With its ability to streamline production, reduce material waste, and eliminate the need for large inventories, additive manufacturing offers a powerful solution to the challenges faced by traditional production models.
About the author:
Catherine is a senior marketing specialist at Mosaic Manufacturing, where she helps bring innovative, on-demand manufacturing solutions to market. Drawing on experience across both startups and corporate settings, she excels at turning complex products into clear, compelling narratives.
