Additive MES: The Quiet Force Behind Scalable Metal and Polymer Production

Authentise Team
Feb 8
3 min read

Updated: Dec 5

Introduction — Additive Manufacturing Can’t Scale Without Additive MES

The additive manufacturing world talks endlessly about machines, materials, and build strategies - but rarely about the hidden system that makes everything work: Additive MES.

While traditional MES systems were designed for predictable, high-volume manufacturing, additive is the opposite:

high mix
complex workflows
variable build times
re-use dependent materials
specialised post-processing
strict qualification requirements

Additive teams that try to scale using generic MES platforms quickly hit a wall. They’re forced to supplement with:

spreadsheets
manual logs
Slack updates
paper travellers
shared drive folders
email chains

The result is fragility, inefficiency, and inconsistent quality.

This is why Additive MES - software purpose-built for the realities of AM - is becoming the difference between experimental production and industrialised manufacturing.

For an overview of what defines it, see: Additive MES Explained

Why Traditional MES Fails in Additive Manufacturing

Additive processes introduce complexities that legacy MES solutions were never designed to handle.

1. Build Prep and Design Revisions Are Central to Production

Traditional MES assumes:

a part
a BOM
a routing

Additive manufacturing requires:

orientation
supports
slicing parameters
design version control
contextual build documentation

Generic MES systems don’t track these inputs effectively.

2. Material Re-Use Cycles Require Precise Control

AM material quality depends on:

re-use cycles
sieving events
blend ratios
contamination checks

This level of granularity doesn’t exist in traditional MES.

See: Future of Material Management

3. Machine Data is Rich, Variable, and Complex

AM machines produce:

melt pool signatures
thermal histories
oxygen levels
power curves
chamber pressure
recoater force
laser data

Most MES systems can’t ingest or contextualise these logs.

4. Post-Processing Isn’t Standardised

Traditional MES expects predictable routings. AM post-processing varies depending on:

geometry
material
customer requirements
certification needs

Additive MES platforms manage this conditional logic automatically.

5. Testing and Qualification Are Entire Workflows

Tensile tests, CT scans, surface measurements, density checks - testing is not something that happens after production. It is part of production.

Additive MES is designed to integrate these steps directly into the workflow.

What Additive MES Actually Does

Additive MES connects every stage of production into a single, traceable workflow.

A. Centralises Design and Build Documentation

No more scattered files. Every revision, support file, slice file, and annotation is stored securely and linked to the final part.

B. Automates Scheduling Across Machines and Work Centres

It considers:

job duration
machine availability
material levels
operator skill
build dependencies

This replaces manual Gantt charts and spreadsheets.

C. Tracks Material Genealogy

Powder → blend → storage → withdrawal → build → post-processing.

This lifecycle tracking is essential for industrial AM.

D. Ingests Machine Data Automatically

Every layer, parameter, and sensor reading ties back into the digital thread.

E. Captures Post-Processing & External Lab Data

Whether:

heat treatment
machining
blasting
CT scanning
tensile testing

All steps become part of the part’s traceable history.

This aligns to programmes like: MABOND Case Study

F. Integrates With the Broader Manufacturing Ecosystem

Additive MES shines when connected to:

quoting tools
ERP
PLM
QA systems
design repositories
machine APIs

As demonstrated in: 3D Spark / Digifabster / Paperless Parts Integrations

Why Additive MES Matters More Than Ever

As AM transitions from prototyping into production, Additive MES becomes foundational for four reasons:

H3: 1. Certification Demands Full Traceability

Aerospace, medical, defence, and automotive auditors expect complete records of:

materials
process parameters
operator actions
testing data

Only Additive MES can make this scalable.

2. Data Complexity Continues to Grow

AM machines are becoming smarter, not simpler.

3: Workforce Turnover Requires Strong Knowledge Capture

Processes that rely on “tribal knowledge” don’t survive growth.

4: Distributed Manufacturing Must Share Data Seamlessly

Additive networks are becoming geographically distributed. MES must support:

multi-site
multi-operator
multi-standard workflows

How to Evaluate an Additive MES System

Before investing, ensure the platform offers:

Must-Have Features

build prep data integration
design version control
automated scheduling
real-time machine connectivity
material genealogy tracking
structured lab/test data ingestion
audit-safe documentation

Advanced Features

API-driven modular architecture
automated routing
predictive analytics
inventory optimisation
digital traveller creation

👉 How to Choose the Best Additive Manufacturing Workflow Software for Your Business

Conclusion - Additive MES Is the Enabler of Industrial AM

Machines matter. Materials matter. Processes matter.

But without Additive MES:

data stays siloed,
workflows stay manual,
traceability stays weak,
quality stays inconsistent.

Additive MES is not an add-on. It is the digital backbone that transforms AM from a promising technology into a scalable manufacturing reality.

Recommended Authentise Tools

Authentise Flows - AM workflow automation
Authentise Materials Management - powder + consumable tracking
Authentise Threads - testing, documentation, lab data
Digital Design Warehouse - secure version control

Ready to Industrialise Your AM Operations?

See how manufacturers are using Additive MES to scale production reliably. Book a demo

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