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Additive Manufacturing in Series Production: Opportunities and Challenges in the Context of Conventional Technologies

18.11.2025

Additive manufacturing has evolved into a key technology for industrial production. In particular, granulate-based Large Format Additive Manufacturing (LFAM) offers new opportunities for the cost-effective fabrication of large-scale plastic parts—not only for prototyping, but also for series production. By using standard or recycled thermoplastic pellets instead of filaments or powders, LFAM significantly reduces material costs while enabling high build rates and large build volumes. For specific applications, this technology is already economically competitive for production volumes of up to 50,000 units, especially when design flexibility, customization, or rapid iterations are required.

This presentation explores the opportunities and challenges of granulate-based LFAM in the context of conventional manufacturing technologies such as injection molding and CNC machining. Key advantages include:

  • Low material costs and broad material availability
  • High throughput with large-scale parts
  • Ability to process recycled materials
  • Suitable for functionally integrated or customized components

However, there are also challenges, including:

  • Limited dimensional accuracy and surface finish compared to traditional methods
  • Post-processing requirements and process stability
  • Lack of standards and certifications for safety-critical applications

Real-world use cases from the automotive, construction, packaging, and tooling industries illustrate where LFAM is already being successfully applied. The presentation concludes with a forward-looking perspective on developments in automation, process monitoring, and industrial integration. Granulate-based LFAM is positioned as a complementary, flexible, and sustainable production method for medium to high volumes in future manufacturing environments.

Speaker: Dr.-Ing. Nicolai Lammert, CEO, YIZUMI Germany GmbH