Use Additive Where It Performs — Use Off-the-Shelf Where It Doesn’t Have To
Not every part in your assembly needs to be printed. In fact, the smartest builds often combine just a few printed components with off-the-shelf hardware — keeping costs down while unlocking performance where it matters.
When to Print
Use additive manufacturing when:
- You need internal geometry or channels
- You’re combining 3+ parts into one function
- You want to reduce assembly time or failure points
- You need fast delivery without tooling
- Geometry is unmachinable or not moldable
When to Buy Off-the-Shelf
Use COTS (commercial off-the-shelf) when:
- The part is purely structural or support hardware
- Geometry is simple and doesn’t affect performance
- You need thread inserts, bushings, or spacers
- It’s a standard size, spec, or catalog item
- Customization offers no clear ROI
How to Mix Them Smartly
- Let additive carry the complexity and function
- Use OTS for mounting, spacing, or sealing
- Design interfaces to accept standard components
- Reduce BOM size without over-customizing
- Build hybrid subassemblies with performance + scalability
Bonus Add-On: Mini “Review Checklist” Box
Quick Assembly Review Questions
- Can 3+ parts be replaced by one functionally?
- Are you aligning or fastening just to hold shape?
- Could internal geometry improve performance?
- Could this assembly be easier to scale with fewer parts?
Want the printable reference version?
Download our checklist for engineers exploring hybrid additive designs.
