How metal 3D printing will power growth in aerospace and energy

Gene Miller, Director of Applications Engineering at Velo3D, a metal 3D printer manufacturer based in Fremont, California, explains the immense impact of their technology: “Metal 3D printing is taking today’s industries to the next level in terms of what can be manufactured. For example, oil and gas components that require processes such as sheet metal stamping and welding can take more than a year to produce using conventional methods. With metal 3D printing, those same parts can often be manufactured in just a few weeks to a few months.”

He also sees broader socioeconomic implications. “In many countries, factories were relocated overseas in search of lower labor costs. This technology does not require the large-scale reconstruction of manufacturing infrastructure. That creates the potential, particularly in the United States, to bring manufacturing back home.”

Gene grew up in eastern Pennsylvania, a region once known for its strong steel industry. There, his father and grandfather both worked for a major steel and shipbuilding company that later filed for bankruptcy in 2001. They were involved in producing large cast and forged components used in ships and bridges. It is perhaps no surprise, then, that he feels a deep commitment to the revitalization of manufacturing in the United States.

That said, even as metal 3D printing technology continues to advance, it does not automatically deliver the best results for every part. In some cases, build speed, precision, or cost may still fall short of expectations. “If used correctly, this technology can deliver outstanding results,” he explains. “But you always have to step back and evaluate from a broader perspective whether a particular part is truly suited for 3D printing.” Gene also emphasizes the importance of identifying a clear need first. “Focus on parts with long lead times, high scrap rates, or complex assembly requirements, or those that are difficult or impossible to manufacture using conventional methods. When you address those kinds of challenges, the likelihood of success with metal 3D printing increases significantly.”

Metal 3D printing is not limited to improving manufacturing processes or supporting the revival of industry. “Traditional methods such as casting, machining, and press forming are reaching their limits in terms of further evolution,” Gene explains. “Adopting metal 3D printing means embracing new technological capabilities for the future.” He believes this technology carries even broader significance. “It is a manufacturing technology that humanity will continue to need and one that must keep advancing. It has the potential to support major goals, such as next-generation power generation and even the possibility of living beyond Earth.”