AMUG 2025: American ingenuity in AM

Say what you want about America (and there is, undoubtedly, a lot being said nowadays), but the level of drive remains unmatched. The notion of the ‘American Dream’ often feels overplayed and diluted; however, having spent the last few weeks stateside, it’s clear why this sentiment persists. AMUG 2025 genuinely felt like an all-American conference in the best possible sense. Unlike some European events, where an air of industry pessimism tends to linger, this gathering radiated optimism and enthusiasm.

Certainly, hosting the event at the Hilton Chicago contributed significantly to its charm. This nearly century-old establishment, once the world’s largest hotel, exudes grandeur and historical character, vastly enhancing the overall experience. Far from a generic, sterile convention center, the building itself has a spirit and charm unmatched by modern venues. Moreover, the hospitality was impeccable, and even the food was notably excellent—though perhaps this praise might reveal a slight bias on my part.

While most attendees were indeed American, the event successfully drew leaders from AM adopter companies worldwide, fostering a diverse yet cohesive atmosphere. Admittedly, the packed schedule proved overwhelming, making it impossible to attend every session. Nevertheless, the event maintained a surprisingly intimate ambiance, connecting individuals unified by their dedication to advancing 3D printing technology.

Among the exhibitors were the expected basic service providers, along with some of the fastest-growing more recent entries in AM, like Axtra3D, which presented the latest advancements in high-speed SLA and materials, Airtech, which presented the latest LFAM parts and materials, and Continuum Powders, which focuses on highly strategic metal reclaiming capabilities for AM.

The AMUG Expo is increasingly identified as a key event for specialized niche providers. Interesting companies like AIM3D (pellet extrusion), Xact Metal and One Click Metal (cost-effective metal PBF), and Freemelt (cost-effective EBM, showing off impressive tungsten 3D printing capabilities) either participated for the first time or are becoming regular exhibitors. Other examples included off-site (due to safety concerns related to hazardous chemicals) support removal services for metal additive manufacturing and innovative electroplating solutions for plastics and resins, notably enhancing component strength. Complementing these were numerous material developers, academic researchers, universities, enthusiastic students, and fresh faces entering the AM space.

Worth the trip

AMUG presentations often show some of the most advanced applications cases for additive manufacturing, including prototyping, modeling, tooling and final parts. At VoxelMatters, we have always been partial to full-scale production applications, and this year’s edition did not disappoint. One of the biggest attention grabbers was the keynote presentation (we also offered a preview), where NASA’s Jet Propulsion Laboratory (JPL)‘s Ryan Watkins showcased their groundbreaking work on 3D printed titanium lattices specifically engineered for the Mars Sample Return mission. These lattices, designed for optimal energy absorption and lightweight structural integrity, are crucial for cushioning Mars samples upon impact during their return to Earth. Leveraging Laser Powder Bed Fusion printers qualified per NASA-STD-6030, JPL has overcome significant manufacturing challenges by implementing post-processing techniques such as etching, achieving densities as low as 2%. The lattice structures have successfully passed Preliminary Design Reviews (PDR) and are moving toward Critical Design Reviews (CDR), marking substantial progress in aerospace AM applications.

While NASA’s applications are some of the most far-out (pun intended), Deutsche Bahn’s (and mga’s) Stefanie Brikwede presented perhaps the most fascinating case of full-scale production. Interestingly, one of the most important production application cases presented came from Europe. Still, Ms. Brickwede’s role in promoting AM adoption is very much global, and she is a regular participant at the AMUG conference. Brikwede presented compelling evidence of AM’s transformative impact on rail transportation during her presentation. Since 2015, DB has rapidly increased its AM-produced parts from just ten to over 150,000 by 2024, achieving savings in the tens of millions of euros. AM is utilized extensively for components in rolling stock and infrastructure, leveraging techniques such as Fused Filament Fabrication, Powder Bed Fusion, and Direct Energy Deposition. DB’s collaborative efforts through the RAILiability initiative—a partnership involving multiple European railway companies—further underscore the significance of AM in sustainable, reliable, and economically efficient railway operations.

Another fascinating application case focused on defense, an increasingly important segment for AM adoption. Established in 2019, Radical Defense equips soldiers and law enforcement personnel with cutting-edge technology. During his presentation, Zack Eskue, the company’s General Manager of Manufacturing, outlined how it initially outsourced its AM but brought these capabilities in-house in 2020–transitioning rapidly from prototyping to full-scale production. It currently operates seven RenAM500Q systems, specializing in Ti6Al4V and Haynes 282 materials. The comprehensive facility integrates AM with CNC machining, testing, and evaluation—including reliability, durability, and environmental assessments—and custom manufacturing solutions supported by 42 machine tools and FANUC robotic systems.

Politics

Since the advent of the latest Trump administration, the industry, much like every other sector, has felt substantial repercussions. Notably, recent travel restrictions preventing American researchers and Department of Defense personnel from attending conferences posed logistical challenges, forcing AMUG organizers to adapt quickly. Ironically, these restrictions occurred despite the defense industry being one of the most significant investors in AM, particularly given the push toward localized production to reduce dependence on foreign suppliers. While the logic behind these governmental decisions remains opaque, the impact on event attendance was clear.

Indeed, this political climate partially explains why attendance was notably reduced to fewer than half of the participants recorded in pre-COVID 2019. Beyond political considerations, general industry sentiment and a crowded event calendar—with the AM Forum in Berlin held the preceding week and RAPID+TCT in Detroit scheduled closely after—also diluted participation.

Despite prevailing geopolitical tensions, the presence of Chinese companies such as Eplus3D and HBD suggests that US-China relations in the AM space have not yet completely soured. Representatives from GoEngineer, who recently partnered with China’s Bright Laser Technologies (BLT), noted that Chinese AM systems remain competitively priced compared to their American counterparts—even accounting for new tariffs. This insight was unsurprising, reinforcing the perception of China’s continued competitive edge in manufacturing efficiency.

General sentiment

One noteworthy trend was the pronounced presence of quality control and non-destructive testing (NDT) providers. The increased emphasis on these services likely signals a broader industry shift toward addressing one of AM’s most significant hurdles: part qualification. More robust, accessible qualification solutions could drive broader adoption across industries with more stringent quality control, such as the automotive and aerospace sectors.

Perhaps buoyed by classic American optimism, the prevailing mood at AMUG 2025 was reassuring. Despite industry challenges and uncertainties, the collective sentiment was optimistic about AM’s long-term trajectory. Presentations featured compelling case studies from medical, automotive, aerospace, and defense sectors, alongside innovative explorations into AI-driven computational design, technical ceramics, cybersecurity, metrology, and beyond. The breadth of applications showcased a resilient and adaptable industry ready to overcome current hurdles.

The discussions emphasized critical strategies for driving AM adoption, focusing on positioning AMg precisely where it offers maximum value rather than forcing its application onto legacy parts that function well enough. The consensus was clear: substitution rarely sparks innovation. Instead, embracing AM’s unique capabilities to create entirely new solutions is essential. One presenter captured this spirit aptly, advising attendees to “Shoot for the moon and let them slap you down along the way up.”