3D printing is a well-established component of prototype development. However, its potential for broader integration within the full manufacturing chain is often overlooked. This oversight is unjustified, argues Radhika Dhuru during her speaker session at Advanced Engineering. She highlights the role of 3D printing as a fully integrated element of the production process—challenging what she refers to as the industry’s ‘new glass ceiling’.
There are so many opportunities being overlooked,” says Radhika Dhuru, Market Manager at Materialise. In her session at Advanced Engineering, she draws a parallel with the well-known glass ceiling—the gender pay gap—and observes that the same principle applies to the persistent undervaluation of 3D printing, or additive manufacturing, today.
“Many companies struggle to scale their prototyping processes into full-fledged manufacturing. They can see the promised land beyond the glass barrier, but have no clear path to get there. In my session, I guide them with practical tips, expert insights, and successful case studies from our portfolio.”
Standardisation, but of what?
3D printing is widely used in prototype manufacturing today. Materialise brings extensive experience in this field, particularly within the aerospace, medtech, and pharmaceutical industries. The technology is fast, flexible, and highly manufacturable. Iteration during the production process can happen at remarkable speed and without excessive cost.
“However, there are two main challenges that companies often face—challenges for which they frequently struggle to find solutions,” says Radhika Dhuru. “The first is standardization. Industry-specific standards are often based on criteria that don’t yet fully apply to 3D printing. Take, for example, the ‘cleanability’ of components—what does that actually mean? At what point is a part considered sufficiently cleanable?”
Addressing this starts with translating such requirements into parameters that are measurable within the context of additive manufacturing. “Surface roughness, for instance. If the roughness falls within a certain range, we can reasonably assume the part meets cleanability standards. In this way, we help companies comply with specific standardization requirements, translating their needs into actionable processes.
Avoiding variability
The second major challenge lies in the variability of the end product. Radhika explains: “Process control is essential. You need to ensure that end products do not vary from one another. Achieving consistency is often the biggest hurdle. At Materialise, we’ve developed software that uses simulation to identify potential errors before moving into mass production. We’ve found that this approach already brings us to a minimal margin of error—making production processes significantly more cost-efficient.”
“We’re not advocating for replacing traditional manufacturing methods with 3D printing,” she continues. “Instead, we position our solutions as a strong added value. For many standardized yet specific components, traditional manufacturing materials can be extremely costly—especially when the parts are intended for single-use. You need a mold, the process takes time… Often, production volumes must reach the tens of thousands to be cost-effective. With 3D printing, that threshold is drastically lower.”
This is how we break the glass ceiling
Radhika therefore calls for collaboration across industry boundaries to help establish the necessary standardization processes and frameworks that ensure repeatability and reliability. “In doing so, 3D printing can make an even greater contribution to scalable success—as a fully integrated part of the production chain,” she concludes.
On Thursday, 22 May, Radhika Dhuru will speak on the Main Stage of Advanced Engineering. Register now viathis link and get inspired by applied cases and the extensive expertise of Radhika and Materialise.
