The Future of Additive Manufacturing: What’s Actually Changed Since 2020?

In 2020, Authentise explored what the future of additive manufacturing (AM) might look like in Week 106 of our News in Review series. The post posed a critical question: Are we truly building a better future with AM - or just layering on old habits in new forms?

Now in 2025, it's time to reflect. What predictions proved accurate? What’s still lagging? And what unexpected trends are now defining AM's evolution?

Let’s take a look.

What’s Evolved in additive manufacturing Since 2019

1. Digital Twin Adoption Is Finally Scaling

The 2020 article speculated that “digital twins” would be key to unlocking the full potential of additive. Today, that’s a reality - especially in sectors like aerospace, defense, and healthcare.

Authentise’s Integrated Digital Twin (IDT) is a prime example of how digital threads have become more than a buzzword. Manufacturers are no longer satisfied with tracking static files - they want dynamic data that evolves with the process.

Then: Conceptual hype Now: Real-world deployment

2. Supply Chain Risk Became Everyone’s Problem

Back in 2020, COVID-19 had just started to expose the fragility of global supply chains. Today, geopolitical tension, raw material shortages, and tariffs have made resilient supply chains a board-level priority.

Additive manufacturing is increasingly being viewed as a critical enabler of localised, on-demand production. As a result, AM workflow software isn’t just about efficiency anymore - it’s about adaptability.

Then: Supply chain warning signs Now: Resilience as a competitive advantage

3. Sustainability Is Gaining Real Teeth

In 2020, sustainability in AM was a goal. In 2025, it’s a requirement.

Companies are now being held accountable for waste, energy use, and lifecycle emissions. Authentise’s tracking tools and automation features help companies identify process inefficiencies, reduce scrap, and report transparently - closing the loop between intent and outcome.

Read more in our post: How Software is Streamlining the AM Workflow.

What Hasn’t Changed (Enough)

• Siloed Systems Still Exist

Despite big promises, many manufacturers are still struggling to connect their design, build, and post-process data. Proprietary systems, poor integrations, and rigid IT policies are slowing down progress.

• Workforce Skills Gaps Persist

Training hasn't kept up with innovation. While the tools are smarter, the human expertise needed to leverage them is still a bottleneck - especially in small and mid-sized operations.

• Not All Software Is Created Equal

Many MES and workflow tools marketed to the AM world are still adapted from traditional manufacturing. Without purpose-built features for additive, they often fail to deliver the promised gains.

Where Are We Heading Next?

• AI-Augmented Process Control: We’re moving from reactive data logging to proactive decision-making.

• Intent-Based Workflows: Not just managing jobs - but understanding why they’re happening.

• Industry Collaboration: Standards, interoperability, and shared data protocols are (finally) on the rise.

Final Thoughts: The Future Is Built on Data - and Decisions

Reflecting on 2020’s predictions, it’s clear: the tools exist, but success depends on how we use them.

Additive manufacturing will continue to grow - but the winners will be those who connect their data, automate their decisions, and adapt quickly. That’s where Authentise comes in.

Ready to future-proof your AM operations? Talk to our team about how Authentise can help you streamline, scale, and lead.

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