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3D printing is a collective term for manufacturing technologies that produce components by successively adding material, usually layer by layer. The industry term for 3D printing is additive manufacturing (AM). The term refers to the additive nature of the technology, where materials are gradually added to form parts, as opposed to traditional manufacturing methods where material is gradually removed from larger blocks to create objects.
Additive manufacturing offers several advantages compared to traditionally manufacturing methods used in industrial production. First, the additive manufacturing process enables the production of geometries that are difficult or impossible to create with traditional manufacturing methods.
Second, the use of additive manufacturing in industrial machine production meets the need for flexibility in an industry that is constantly evolving. Producing metallic prototypes of machine parts using additive manufacturing allows iterations, concepts, and manufacturing methods to be tested in a cost-effective way before scaling to full serial production.
Third, supply chains can be optimized and streamlined when additive manufacturing methods are used. The need to outsource parts of a manufacturing process is reduced, and local production of components is made possible, which also reduce environmental impact and mitigate risks associated with supply chains.
Finally, the expected performance and quality advantages of additive manufacturing methods compared to traditional manufacturing should be mentioned. Well-developed additive manufacturing systems can surpass traditional methods in terms of topology optimization, functional integration possibilities, and overall efficiency.
AM as a manufacturing method is currently growing rapidly, and Freemelt operates specifically in the market for metal 3D printing (also known as metal additive manufacturing).
In 2023, the global market for metal additive manufacturing was valued at approximately EUR 3 billion1. The estimate includes the value of sales of 3D printers, powder and services. The market for metal additive manufacturing is expected to grow at a CAGR (compound annual growth rate) of approximately 20% through 20282.
Metal additive manufacturing creates new opportunities, especially in industries such as defense, energy and medical technology, where complex and high-performance components are in demand. Tungsten, which is still in an early stage of the transition to AM, has great growth potential due to its unique properties, such as its extremely high melting point. This makes tungsten particularly suitable for applications in the energy and defense industries. Tungsten applications are less regulated, and competition is still relatively undeveloped. As more industrial players discover the possibilities of 3D printed tungsten, the market is expected to grow rapidly in the coming years.
Defense
The defense industry has high demands on material properties since products are subject to extreme stress. Current manufacturing processes for defense materials often rely on global supply chains, including imports from suppliers and subcontractors located in countries that, for geopolitical reasons, are now considered unsuitable to be part of the supply chain.
As a result, there is a growing trend in the market to turn to companies established regionally for outsourcing and supplier relationships, a practice known as “near-shoring.”
The global defense industry is expected to grow from USD 473 billion in 2024 to USD 682 billion in 2029, with a CAGR of approximately 7.7%3. NATO’s recent commitment for member states to allocate 5% of GDP to defense is set to have significant and lasting impacts on both the defense sector and the broader economy4. Addressing modern security challenges will require not only increased funding but also the development of advanced technologies that enable faster and more efficient production. At the same time, the EU has launched an initiative to mobilize up to USD 870 billion in investments over four years to bolster Europe’s defense industry and military capabilities5.
The use of additive manufacturing in the defense industry is increasing rapidly, with an adoption rate expected to reach 19% by 20356. The US Department of Defense is expected to invest approximately USD 414 million in research for additive manufacturing in 20257.
Copper and tungsten are important materials in the defense industry due to properties such as high heat resistance and penetration capability. Freemelt has several collaborations within the defense industry, with companies including Saab Dynamics and industrial companies in the US.
Renewable energy
The market for additive manufacturing is currently experiencing increased demand from the energy sector. The increase is primarily driven by the development of fossil-free energy, a trend expected to continue in the coming years. A driving force behind the demand is the energy sector’s need for heat- and radiation-resistant applications. Additive manufacturing enables geometries that could not previously be made from materials with properties suited for exposure to extreme temperatures. This is of great importance to the energy sector, which use advanced technologies and systems. Fusion is a technology currently undergoing significant development. Test reactors are being built, and tungsten has proven to be a highly interesting material due to its heat- and radiation-resistant properties. The expectations are that fusion will help address the Earth’s climate challenges, why large investments are made in several countries to validate the technology8.
The fusion energy market is growing rapidly, and the number of commercial fusion companies has doubled in the last five years. Three of those have amassed more than USD 1 billion in investments. Furthermore, total investments in fusion energy until 2025 amounted to USD 9.8 billion9. The development has been mainly driven by large projects in fusion research, but also by larger investments made by private players such as Commonwealth Fusion Systems.
Freemelt’s research machine, Freemelt® ONE, is designed for research and development, offering flexibility across various metals and applications. Most of the machines sold are used for tungsten development. Freemelt has established collaborations in tungsten and fusion energy with leading institutions, including the University of Wisconsin, UK Atomic Energy Authority (UKAEA), University of Birmingham, and University of Sheffield, along with several other partners and customers in the field. Furthermore, UKAEA has invested in Freemelt’s industrial printer, e–MELT®, to expand and accelerate the adoption of 3D printed parts in fusion applications.
MedTech
Additive manufacturing has been used in the MedTech industry close to 20 years, making it the sector with the highest adoption rate of AM for serial production. One application that is already in serial production through AM is orthopedic implants made of titanium. Additive manufacturing is often used for such production as it enables additive manufacturing of materials that mimic the connective tissue in the human bone structure, improving bone ingrowth.
The global market of orthopedic implants is expected to grow from USD 55 billion in 2024 to USD 86 billion in 2032, with a CAGR of 5%10. The market for 3D printed implants is expected to grow from USD 1.7 billion in 2024 to USD 6.6 billion in 2033, with a CAGR of 16% during 2025-203311. The global market for orthopedic implants is one of the major target markets for Freemelt, and demand for AM produced products is expected to increase. Freemelt has established collaborations with two global manufacturers of orthopedic implants (Original Equipment Manufacturers, ”OEM”).
With a complete product and service offering, Freemelt is well positioned to meet the increased demand in its focus segments, defense, energy and MedTech technology