The Rise Of Additive Manufacturing

In today’s fast-paced world, businesses are always on the lookout for ways to produce faster, more flexibly, and at lower costs. One technology that’s making waves is 3D printing—specifically masked stereolithography (MSLA)—and it’s set to challenge one of the most established methods of production: plastic injection molding.

While injection molding has long been the gold standard for producing large volumes of identical parts, the high costs, inflexible setup, and difficulty in adapting quickly make it a tough fit for the demands of today’s market. 3D printing is rapidly changing this landscape, offering a level of flexibility and efficiency that’s simply unmatched.

Breaking Down the Benefits of 3D Printing over Injection Molding

1. Cost Efficiency

Traditional injection molding comes with high initial costs due to the need for custom tooling and molds. With 3D printing, you can skip these setup costs entirely, making it ideal for smaller production runs or projects where design changes are frequent. Imagine being able to produce only what you need, exactly when you need it, without costly upfront investments!

2. Rapid Iteration and Design Flexibility

Unlike injection molding, which requires retooling for every design change, 3D printing allows you to make instant adjustments. You can test, refine, and bring new ideas to life without disrupting production or incurring high costs. This rapid prototyping capability empowers businesses to innovate faster and respond to customer demands with ease.

3. Scalability Without the Risk

One of the biggest advantages of MSLA is its ability to print in large batches, making it competitive even for higher-volume production. Need to produce 10 parts or 1,000? 3D printing can scale up or down with no need for inventory, enabling businesses to test markets with limited runs or ramp up as demand grows.

4. Precision and Quality

 MSLA technology offers an incredible level of detail and accuracy, often achieving precision within 0.035mm. The result? High-quality parts that look and feel like injection-molded products—often with little to no post-processing required. The smooth finish and complex geometries achievable with MSLA open doors to designs and structures injection molding can’t replicate.

 3D Printing in Action: A Case Study with Adidas

One standout application is in the footwear industry, where Adidas partnered with Carbon 3D₁ to develop high-performance midsoles using Digital Light Synthesis (DLS), a cutting-edge SLA technique. This collaboration resulted in custom lattice structures that provide unique cushioning and responsiveness, demonstrating how SLA technology can create products with unprecedented speed, quality, and customization.

What Lies Ahead?

While 3D printing is already revolutionizing certain markets, there are still scenarios where injection molding has the upper hand—particularly in producing large parts or meeting specific industry certifications. However, as MSLA technology continues to evolve, with improvements in speed, material diversity, and machine size, we could soon see it take on larger-scale applications, further cementing its role in modern manufacturing.

For early adopters, the next competitive edge might just be one print away. By embracing 3D printing now, businesses position themselves to lead as this technology continues to advance.

Stay Ahead of the Curve

Thanks for tuning in to this edition of The Additive Advantage. If you found this valuable, feel free to share it, and don’t hesitate to reach out with any thoughts or questions. Looking to dive deeper? Check out our latest articles on how 3D printing is transforming industries across the board.

Until next time,

The Additive Advantage Team

P.S. If you're curious to explore how additive manufacturing can fit into your production strategy, keep an eye out for our upcoming guides.