Is the Next Big Leap in Additive Manufacturing Fueled by Metrology?

As we move through 2025, the convergence of metrology and additive manufacturing (AM) is not merely a technological evolution; it is a paradigm shift poised to redefine the competitive landscape of manufacturing.

In an era where precision and innovation are paramount, the role of metrology in additive processes is becoming indispensable. This intricate dance between measurement science and 3D printing is unlocking unprecedented opportunities for efficiency, accuracy, and collaboration. By integrating advanced metrology techniques into AM, industries across all sectors are not just keeping pace with change—they are setting the stage for a new era of manufacturing excellence.

This trend highlights how metrology is poised to elevate AM to new heights and foster a future where quality and creativity go hand in hand.

The Unique Role and Challenges of Metrology in AM

AM allows for the creation of complex, organic shapes that were previously impossible or impractical with traditional manufacturing methods. This revolutionary capability, however, presents new challenges for teams and dictates the need to evolve traditional metrology processes.

The more complex and intricate shapes that AM processes produce necessitate a nuanced understanding of geometric dimensioning and tolerancing to ensure components meet more complicated design specifications. This can be particularly challenging in industries such as aerospace and medical design, where the integrity of each component is crucial, as any deviation can significantly impact functions such as airflow or blood circulation. As AM continues to advance, the metrology sector must adapt to measure these intricate geometries accurately, thus ensuring that components are both dimensionally correct and structurally sound.

Additional challenges may arise for teams due to the traditional, siloed approach to the metrology and design processes; an approach that is especially problematic in AM due to its innate complexity.

Traditionally, metrology and design teams work in silos, with each metrologist potentially using their own measurement methods, resulting in varied outcomes. When dealing with the unique geometries of 3D-printed parts, collaboration and communication between teams is crucial in order to avoid compromises in accuracy.

Bridging this gap will be essential to achieve consistent, reliable outcomes without requiring engineers to become metrology experts. As we move forward, creating a seamless integration between measurement strategies and design processes will be key to unlocking the full potential of AM.

Advancements in Metrology Software and AI integration

The future of metrology in AM is closely linked to advancements in software and artificial intelligence (AI). Metrology software is evolving to include simulations that confirm designs and improve production lifecycles. These virtual prototypes can more accurately predict and prevent quality issues, reducing the time and cost associated with physical prototyping.

AI integration is set to enable closed-loop dynamic inspection systems. These systems will guide teams on what to inspect, allowing for more targeted and efficient quality control. By incorporating AI into simulation workflows, manufacturers can better understand how geometric features correlate with potential defects, ensuring that parts can withstand the forces and tolerances they will encounter in real-world applications.

Structural Integrity and Non-destructive Evaluation

In the coming years, the metrology field will expand its focus beyond dimensions and product manufacturing information to include structural integrity assessments. Techniques such as CT scanning, ultrasonics and surface roughness evaluation will become increasingly important in AM.

This shift in focus is notably relevant for applications like hypersonics and medical stents, where the failure of a single component can have catastrophic consequences. As AM becomes more mainstream, engineers will need to expand their knowledge of metrology and finite analyses to ensure that parts meet both dimensional and structural requirements.

Trends and Innovations for 2025

Several key trends and innovations are set to shape the landscape of metrology in AM throughout 2025:

Mesh compensation tools. These tools will play a crucial role in aligning virtual or actual printed parts with their design counterparts. By finding the best fit and minimizing errors of deviation, mesh compensation tools calculate deformation fields to compensate the direction the part is being warped to enhance accuracy and reduce iterative production times, versus performing an actual/nominal comparison that only looks normal to the surface walls. This technology will be particularly valuable in applications where geometric precision is critical.
Adaptive measurement templates. These templates will streamline the measurement process by adapting the measurement plan with tolerances using the deformation field for a non-linear search in all directions, versus a cone or vector probing technique which is a linear search that can oftentimes create errors on the recreated geometric elements. In so doing, it reduces the amount of rework and minimizes errors. Adaptive measurement templates will accelerate the prototyping and design phases, cutting production times from months to weeks.
Shift left mentality. The democratization of metrology will bring design, manufacturing and inspection phases closer together in connected digital systems. This shift-left approach will enable manufacturers to detect, identify and resolve potential quality issues earlier in the production process, improving efficiency and reducing costs.
Tailored material properties. As AM processes become more complex and automated, maintaining accuracy will require a deeper understanding of material properties. Engineers will need to explore new materials and process parameter variations to achieve the desired balance of strength, weight and structural integrity.
AI-driven innovation. The integration of AI into metrology and AM will unlock new possibilities for innovation. AI will help create unique libraries of material types and properties, enabling manufacturers to tailor their processes to specific applications and improve overall product quality.

Embracing Opportunities for 2025 and Beyond

Despite these exciting trends, several challenges remain in the integration of metrology and AM. The complexity of 3D-printed parts and the variability of materials can complicate measurement processes. Additionally, the need for high precision in critical applications demands continuous innovation in metrology techniques and tools.

To overcome these challenges, manufacturers must embrace a culture of collaboration and continuous learning. Engineers will need to break out of traditional silos and engage with metrology experts to ensure that their designs meet both dimensional and structural requirements. By fostering a collaborative environment and leveraging the latest technologies, manufacturers can unlock the full potential of AM and drive the industry forward.