Wohlers Report 2020: Unveiling Key Trends and the Industrialization of Additive Manufacturing

Every year, the esteemed American firm, Wohlers Associates, Inc., meticulously compiles and unveils its industry-leading report, offering unparalleled insights into the dynamic world of additive manufacturing (AM). The Wohlers Report 2020 marks a significant milestone as its 25th edition, providing an exhaustive and wide-ranging analysis of the latest developments, innovations, and overarching trends shaping the AM market. Spanning an impressive 380 pages, this comprehensive report is an invaluable resource, packed with a wealth of information concerning the growth trajectory of the AM industry. It highlights over 250 concrete examples of AM applications currently in production or under advanced development, illustrating the tangible impact and expanding versatility of 3D printing technologies across diverse sectors.

Looking back, the Wohlers Report 2019 notably emphasized the robust growth observed in 3D printing materials, with a particular focus on metals. This preceding report illuminated a pivotal shift, detailing how revenue generated from metal additive manufacturing processes had soared by an impressive 41.9%. This substantial increase underscored the growing industrial adoption of metal AM, driven by its capacity to produce strong, durable, and complex parts suitable for demanding applications. The most prevalent and impactful process identified in this surge was Laser Powder Bed Fusion (LPBF), a technology increasingly leveraged for its precision and ability to create intricate geometries. Beyond its traditional role in rapid prototyping, AM technology was clearly being embraced for industrial-scale production. Concurrently, the report observed a notable trend: desktop 3D printers experienced a significant decrease in their annual growth rate, signaling a maturation of the consumer and prosumer markets and a broader industry focus shifting towards professional and industrial solutions capable of higher performance and reliability.

Throughout 2019, various other industry reports and market analyses corroborated this evolving landscape, reinforcing the narrative of a fundamental change within the additive manufacturing ecosystem. An increasing number of manufacturers expressed keen interest in integrating 3D printing technologies not just for prototyping, but for full-scale production. This paradigm shift is fueled by a compelling set of benefits that AM offers, including the promise of true mass customization, significantly lower production costs attributed to reduced tooling and material waste, and dramatically shorter lead times that enhance supply chain agility. The Wohlers Report 2020 vividly illustrates this transformation with the compelling case of Jabil, a prominent American worldwide manufacturing services company. Jabil successfully redesigned an impeller for manufacturing using additive manufacturing techniques. This innovative approach allowed them to replace an assembly of 73 distinct metal parts, traditionally joined by hand, with a single, integrally printed component made from a fiber-reinforced polymer composite. This not only streamlined the production process but also yielded astonishing efficiency gains, enabling the production of fifty impellers in the same timeframe it previously took to manufacture just one. This example powerfully demonstrates AM’s potential to revolutionize part consolidation, material optimization, and overall manufacturing speed.

Furthermore, the report underscores a critical maturation point for additive manufacturing: a growing proportion of users are now actively producing functional, end-use parts, moving beyond jigs, fixtures, and prototypes. The Wohlers Report 2020 meticulously details and analyzes the various maturing and emerging applications of AM specifically tailored for series production. This shift is a testament to the increasing reliability, repeatability, and cost-effectiveness of industrial 3D printing systems. A prime example highlighted in the report, which garnered significant attention last year, is the strategic collaboration between HP and Volkswagen to 3D print parts at scale. This ambitious partnership saw the German car manufacturer install an impressive fleet of 90 HP 3D printers across its factories, enabling the rapid production of 10,000 functional parts within a mere few weeks. Volkswagen’s long-term objective is even more ambitious: to leverage this technology to print between 50,000 to 100,000 functional parts annually, each roughly the size of a football. This initiative demonstrates how AM can support agile manufacturing, create lightweight components, and optimize supply chains for both new vehicles and spare parts, ultimately driving innovation in automotive production.

Beyond specific applications and market shifts, the Wohlers Report 2020 delves deeper into the foundational elements driving the global AM industry. It provides comprehensive analyses of patent activity, tracking innovation and intellectual property trends; scrutinizes the vibrant landscape of startups and the significant investment flowing into the sector; and explores the critical role of research and development (R&D) in pushing technological boundaries. The report’s unparalleled depth and accuracy are attributed to its robust methodology, building upon input from a record-setting ensemble of contributors. This includes valuable insights from 129 service providers, directly engaged in delivering AM solutions; 114 manufacturers of industrial additive manufacturing systems, representing the forefront of hardware innovation; and 40 producers of third-party materials and desktop 3D printers, covering the entire supply chain. Furthermore, the report meticulously documents government-sponsored research and development initiatives, highlighting strategic national and international investments in AM. It also sheds light on crucial collaborations and consortia, which foster industry-wide standards and accelerate technological adoption. The activities of 139 academic and research institutes around the world are also integrated, showcasing the foundational scientific work underpinning future AM advancements. The sheer breadth of expertise captured in the report is remarkable, with 79 co-authors and contributors spanning 33 countries providing diverse expert views and opinions, ensuring a truly global and holistic understanding of the additive manufacturing market. For those seeking even more detailed information and direct access to the source, additional resources are available HERE.

The Wohlers Report 2020 unequivocally illustrates that additive manufacturing has firmly transitioned from a niche prototyping tool to a mainstream industrial production technology. The comprehensive data and case studies presented within its pages paint a clear picture of an industry poised for sustained growth, driven by innovation in materials, process improvements, and increasing adoption for functional, end-use applications across various sectors. The insights gleaned from this landmark 25th edition are crucial for businesses, researchers, and policymakers alike, providing a definitive benchmark for understanding the current state and future trajectory of 3D printing. It highlights the continued importance of material science advancements, the growing demand for highly reliable and scalable industrial systems, and the transformative potential of AM in creating more efficient, customized, and resilient manufacturing processes globally. As the industry continues to evolve at a rapid pace, reports like this are vital for navigating its complexities and capitalizing on the immense opportunities it presents.

What are your thoughts on the pivotal trends highlighted in the Wohlers Report 2020 and the ongoing industrialization of additive manufacturing? We invite you to share your insights and comments below, or engage with us on our vibrant community pages on Facebook and Twitter! To stay completely up-to-date with all the latest news, breakthroughs, and developments in the world of 3D printing, don’t forget to sign up for our free weekly Newsletter, delivered directly to your inbox!