InShaPe - Metal 3D Printing Revolution

A breakthrough in metal additive manufacturing has emerged from Germany—and it’s not just a laboratory experiment. Under the EU-supported InShaPe project, researchers at the Technical University of Munich (TUM) and industry partners have developed a next-generation laser metal deposition system that redefines what’s possible in high-performance 3D printing.

What InShaPe Delivers: Notable Performance Gains

• 6× productivity increase in laser metal deposition

• 50% lower manufacturing costs

• Lower energy consumption and material waste

• Improved part quality for demanding sectors like aerospace and energy

These gains come from dynamically adjusting the shape and intensity of the laser beam in real time, depending on material properties and geometries. Combined with advanced imaging, the system monitors melt pools with a level of granularity rarely seen in industrial additive setups.

Why This Matters for Contract Manufacturing

For contract manufacturers, especially those serving aerospace, defense, and energy clients, this technology could shift the economics of low-volume, high-complexity parts.

Here’s what changes:

• Faster turnaround times on complex geometries
• Less post-processing thanks to cleaner surface finishes
• Material savings that reduce cost-of-goods without compromising performance
• Sustainability metrics (waste, energy use) that help meet client ESG goals

Crucially, this isn’t replacing CNC—it's expanding what's possible when additive and subtractive processes are integrated.

Implications for Precision CNC Shops

For precision machine shops, the InShaPe breakthrough doesn't signal competition—it signals convergence. As 3D-printed near-net-shape components become more accessible and higher quality, CNC shops may find:

• New roles in hybrid manufacturing chains (finishing, verifying, adapting additively manufactured parts)
• Reduced roughing time, especially on difficult-to-machine alloys
• Expanded capability portfolios for prototyping, tooling, or repair tasks
• More value-added contracts from clients looking to combine speed, cost, and precision

Shops that already offer EDM, hard milling, or post-print machining may benefit most.

Technology with Real-World Fit

The team at TUM emphasizes that the InShaPe system isn’t just a lab prototype. It was designed with real-world deployment in mind, targeting:

• Industrialization-ready throughput
• Compatibility with standard alloys
• Modular integration into existing additive lines

That means adoption won’t require custom material systems or rewriting entire processes—a major barrier in other AM technologies.

The Strategic Takeaway

InShaPe represents more than a technical win. It offers a glimpse into the future of adaptive, sensor-rich, AI-controlled manufacturing—where process control happens in real time, not through trial-and-error cycles.

For contract and CNC manufacturers, the message is clear: hybrid workflows are getting smarter. Those who invest early in integrating additive capabilities—or partner with shops that do—can win both in speed and cost-sensitive markets.

As beam control gets smarter, manufacturing does too. The InShaPe project shows that AI-driven innovation isn’t about replacing traditional processes—it’s about making every step sharper, faster, and more precise.

About MDCplus

Our key features are real-time machine monitoring for swift issue resolution, power consumption tracking to promote sustainability, computerized maintenance management to reduce downtime, and vibration diagnostics for predictive maintenance. MDCplus's solutions are tailored for diverse industries, including aerospace, automotive, precision machining, and heavy industry. By delivering actionable insights and fostering seamless integration, we empower manufacturers to boost Overall Equipment Effectiveness (OEE), reduce operational costs, and achieve sustainable growth along with future planning.