Why Materials Are Still the Biggest Problem in 3D Printing—and How RapidMade Is Solving It

Let’s be honest—when most people think of problems in 3D printing, they picture a clogged nozzle or a part that warps off the build plate. But in industrial-scale additive manufacturing, the real challenges go way deeper. The biggest one? Materials.

Yep, that’s right. Not machines. Not software. Not even print speed. It’s the stuff we’re trying to print with.

A recent survey from Jabil, which polled 200 decision-makers in the additive world, put it plainly: 90% of respondents said the materials they actually need just aren’t available—at least not in the form or certification level they require.

So if you’ve been wondering why 3D printing hasn’t totally taken over traditional manufacturing yet, this is a huge reason why.

Everyone Wants Better Materials—But Can’t Get Them

It’s not that the industry hasn’t made progress. Far from it. Today’s printers can do amazing things with plastics, metals, and composites. Companies are using carbon fiber-reinforced polymers for tooling, biocompatible titanium for implants, and flame-retardant materials for aerospace parts.

The problem? Most of those materials are hard to source, expensive, or stuck in regulatory limbo.

Sure, you can print with basic PLA or nylon all day. But if you need something UL-certified, ISO-rated, or FDA-cleared, good luck. The survey showed that even companies who want to use advanced metals and polymers often hit a wall when it comes to certification and cost.

In fact, 74% of respondents called material cost a top financial barrier, especially when it comes to high-end stuff like Inconel, ULTEM, or custom-engineered blends.

Custom Materials Sound Great—Until It’s Time to Scale

More than half of the companies surveyed are already using custom-formulated materials for specific performance needs—like RF shielding, heat resistance, or bio-safety. That’s awesome. But it comes with a big downside: long lead times, high development costs, and painful qualification processes.

And here’s the catch—if you can’t scale that custom material quickly and affordably, it’s tough to move beyond small pilot runs. That’s a big reason why so many 3D printing programs get stuck in the R&D phase instead of going full production.

Beyond the Print: Scaling Is Still a Grind

Even when companies manage to source the right material, they hit the next hurdle: post-processing.

Support removal, heat treating, surface finishing, inspection—it all adds up. Half of the survey respondents said post-processing costs are a major scaling issue. And if you’ve ever printed something in metal, you know this is no joke.

Plus, many shops still struggle to plug their 3D printing operations into their existing systems. ERP, MES, PLM—all those big software acronyms—don’t always play nice with AM workflows. That means more manual steps, more headaches, and less traceability.

Enter RapidMade: Material Experts + Manufacturing Muscle

So what’s the fix? It’s not just a better printer—it’s a smarter partner.

RapidMade is one of those rare companies that understands both the material science and the manufacturing strategy behind successful additive production. They’re not just a print shop—they help companies move from “we’d like to use this material” to “we just printed 5,000 parts and passed inspection.”

They offer:

• Certified polymers, composites, and metals for demanding industries
  
  
• Custom feedstock formulation and process tuning
  
  
• ISO 9001-certified post-processing and testing
  
  
• Scalable production from prototype to low- and mid-volume runs
  
  
• Design support for material-specific performance (aka “print it right the first time”)
  
  

Whether you’re trying to qualify a new material, print a mission-critical aerospace part, or just scale up your existing AM workflow, RapidMade is built to help you get there—without reinventing the wheel.

Final Thought: It’s Not Just What You Print—It’s What You Print With

We’ve hit a tipping point in additive manufacturing. The machines are ready. The designs are getting smarter. But until materials catch up—and companies know how to use them effectively—we won’t see full-scale adoption.

If your business is stuck waiting for the right materials or unsure how to qualify and scale them, it might be time to bring in the pros.

Want to print smarter with the right materials?
 Visit www.RapidMade.com or reach out to [email protected].
We offer some of the best 3D printing services on the planet.