Aluminum castings are an indispensable element in the Japanese manufacturing sector, particularly within the automotive and industrial machinery industries. However, traditional manufacturing methods reliant on “molds” are beginning to reach their limits in the face of recent challenges, such as the shift toward high-mix, low-volume production, the need for shorter prototyping periods, and the necessity of ensuring supply chain flexibility.
As a result, Aluminum 3D Printing technology is garnering significant attention. “Mold-less manufacturing,” which creates parts directly from 3D data without the need for physical molds, enables the suppression of initial investment and a dramatic reduction in lead times. This article provides a thorough analysis—based on quantitative data as of 2026—of the latest market trends, technical advantages, and the challenges associated with implementation. We hope this serves as a valuable resource for procurement and purchasing managers in formulating their next-generation sourcing strategies.
The Accelerating Metal 3D Printing Market and the Rise of Aluminum
Metal 3D printing (Additive Manufacturing: AM) is no longer merely a tool for prototyping. It is rapidly being implemented across society as a viable means for end-use product manufacturing.
Market Size Trends Globally and in Japan
According to research data, the global 3D printing market was valued at approximately USD 1.6 billion in 2025 and is projected to reach USD 4.012 billion by 2035 (CAGR 6.7%). Growth in the Japanese domestic market is particularly remarkable, expected to expand from USD 170 million in 2025 to USD 820 million by 2033, representing an exceptionally high average annual growth rate of 19.1%.
Among various materials, “Aluminum” is positioned as the segment with the highest growth potential—surpassing titanium and stainless steel—due to its lightweight properties and high thermal conductivity. In Japan’s metal 3D printing market, revenue related to aluminum is forecast to grow at a CAGR of 18.1% from 2024 to 2030, quickly becoming a mainstay on the manufacturing floor.
Three Disruptive Changes Brought by “Mold-less Manufacturing”
- Elimination of Initial Costs: The need for aluminum die-casting molds, which traditionally required investments of millions to tens of millions of yen, is eliminated.
- Minimization of Lead Times: The months-long period required for mold fabrication is reduced to zero, allowing physical parts to be obtained within days of data transmission.
- Liberation of Geometric Freedom: Features impossible with traditional casting, such as “internal hollow structures” and “lattice structures” (lightweight web-like designs), become feasible, making a 30% to 50% weight reduction a reality.
Technical Superiority and Case Studies of Aluminum 3D Printing
The evolution of aluminum 3D printing, specifically Powder Bed Fusion (PBF) and Directed Energy Deposition (DED), has reached a level that complements or even replaces conventional casting technologies.
1. Shortened Cycles through Drastic Improvements in Cooling Efficiency
3D printers have made it possible to place complex cooling water channels “inside” the mold. In a case study by Toyota Industries Corporation, 3D modeling was adopted for the molds of car air-conditioning compressor parts to optimize the cooling structure. As a result, defects caused by material adhesion were reduced by 15%, contributing significantly to the stable operation of the production line.
2. Simplification of Procurement Management via Part Consolidation
Structures that previously required joining 10 separate aluminum parts via welding or bolting can now be integrally molded as a single part using a 3D printer. This “Part Consolidation” not only reduces the number of components but also enables a reduction of over 50% in inventory management costs and quality inspection processes.
3. Cost Benefits for High-Mix, Low-Volume Production
For parts with annual production volumes of a few hundred units or less, the depreciation of mold costs is a significant burden. Although the unit price per kilogram of aluminum powder is on an upward trend, the break-even point is rising annually when considering the benefit of zero mold investment. As of 2025 estimates, for parts with complex geometries, 3D printing is increasingly becoming more cost-effective in terms of total cost for volumes up to approximately 500 units per year.
Three Barriers to Implementation and Their Solutions
On the other hand, not all aluminum casting will be replaced by 3D printers. It is important to address the realistic challenges faced by management.
Challenge 1: Material Cost and Throughput (Production Speed)
The price of aluminum powder remains high compared to standard ingots. Additionally, the process of building up layers one by one takes time.
- Solution: Since 2025, the proliferation of multi-laser machines (which fire multiple lasers simultaneously) has increased build speeds by 2 to 3 times compared to conventional models. Furthermore, the establishment of powder “recycling technology” has made it possible to keep waste loss below 10%.
Challenge 2: Surface Roughness and Post-Processing
In the “as-built” state (immediately after printing), surface roughness is similar to that of sand casting (approximately Ra 10–20 μm).
- Solution: Design for Additive Manufacturing (DfAM) is employed, assuming additional processing by machining centers for final mating surfaces or seal faces. “Hybrid manufacturing,” combining 3D printing with subtractive machining, is the current industry standard.
Challenge 3: Quality Assurance and Certification
Unlike traditional castings, there are concerns regarding internal defects (porosity) unique to 3D printed parts.
- Solution: Non-destructive testing using CT scans and in-process monitoring technologies during builds have evolved significantly. The increasing adoption in the aerospace sector serves as a testament to this reliability.
Conclusion
Aluminum 3D printing technology is no longer a “technology of the future”; it is a “strategic option” for the manufacturing floor of 2026. The speed and flexibility afforded by mold-less manufacturing serve as powerful tools in today’s highly uncertain supply chain environment.
For the Japanese manufacturing industry to maintain its competitiveness, the key lies in integrating the “high-value-added, ultra-short lead time” domain—where 3D printing excels—alongside the traditional pursuit of “mass production and low cost.” While challenges such as high initial machine costs remain, the return on investment is extremely high when evaluated holistically, including reduced management costs through part consolidation and the acceleration of development cycles via mold-less processes.
As a first step, why not identify parts from your existing inventory that meet the three criteria of “low volume,” “long lead time,” and “complex geometry,” and begin evaluating them for 3D printing replacement? At Daiwa Aluminum Vietnam, we merge traditional casting expertise with the latest digital manufacturing to support our customers in building an optimal procurement portfolio. In 2026, aluminum 3D printing has made mold-less manufacturing a reality, changing the common sense of the manufacturing industry. With a domestic market growth rate exceeding 19% annually, it has become the key to cost reduction and shorter lead times. Experts explain the latest market statistics, Toyota Industries’ success stories, and the challenges and solutions for implementation in detail.