Additive Manufacturing Takes Off: From Prototyping to Production in Aerospace

South Carolina is emerging as a significant hub for additive manufacturing as major industrial players like Boeing, BMW, and Volvo transition the technology from prototyping to full-scale production. This shift is supported by a robust ecosystem of specialized firms such as 3D Systems and CADmore Metal, alongside substantial investments in academic research facilities like Clemson University’s $130 million Advanced Materials Innovation Complex. For the additive manufacturing sector, this regional growth demonstrates the increasing viability of 3D printing for critical aerospace, automotive, and medical components.

Major aerospace and automotive manufacturers in South Carolina are integrating additive manufacturing (AM) into their core operations to reduce waste and streamline production. Boeing utilizes AM at its North Charleston 787 Dreamliner plant to produce interior components like ducts and specialized production tools, while BMW Group and Volvo USA employ the technology for manufacturing aids and pre-production updates such as test fitting. Beyond these giants, 3D Systems—founded by AM inventor Chuck Hull—continues to expand its Rock Hill operations, supplying metal and polymer products to global partners like Align Technology for dental devices and NuVasive for spinal implants.

The regional landscape is further diversified by specialized startups and new technological implementations, such as Columbia-based CADmore Metal, which introduced Cold Metal Fusion (CMF) in 2024. This process allows for the production of high-strength metal parts, including titanium, at lower costs compared to traditional methods. Additionally, the New Forge facility in Rock Hill, a collaboration between CERN and the state’s Site and Civil Engineering Department, provides startups and students with access to workspace and 3D printers for prototyping. Industrial growth is also evidenced by AIRSYS Cooling Technologies, which is constructing a $40 million headquarters in Woodruff that will utilize AM for data center cooling solutions.

To sustain this growth, South Carolina has invested heavily in workforce development and research infrastructure. Clemson University recently opened its 143,000-square-foot Advanced Materials Innovation Complex, a $130 million facility dedicated to interdisciplinary research and lab space. Similarly, Greenville Technical College’s Center for Manufacturing Innovation (CMI) and the Southeastern Institute of Manufacturing and Technology (SiMT) provide specialized training and business incubation. These institutions, supported by the South Carolina Manufacturing Extension Partnership (SCMEP), bridge the gap between conventional manufacturing and high-tech additive processes, ensuring a pipeline of personnel skilled in turning computer-generated designs into physical products.