There’s a persistent myth in manufacturing that metal 3D printing is always more expensive than traditional machining. While this may hold true for simple, high-volume parts, the economics shift drastically when complexity enters the equation. For intricate designs, printing can actually be cheaper and faster.
Machining complex geometries often requires multiple setups, specialized tooling, and custom fixtures, each adding to the overall cost. Moreover, intricate parts may require EDM or 5-axis machining, which further escalates time and labor. In contrast, metal additive manufacturing handles complexity with ease. Features like internal channels, organic shapes, or lattice structures can be built directly into the part without additional cost or steps.
Another cost advantage is the consolidation of parts. Instead of machining and assembling a dozen components, AM allows engineers to build them as a single unit, reducing material waste, assembly time, and potential failure points. This is particularly beneficial for low- to mid-volume runs, or for on-demand manufacturing where lead times matter.
In industries like aerospace, medical, and energy, these savings are not just financial, they’re strategic. Engineers can rapidly iterate, test, and deploy without waiting weeks for tooling or CNC capacity. So while it’s true that AM materials and printers come at a premium, the overall value proposition for complex parts often makes 3D printing the smarter, faster, and ultimately cheaper choice.