Additive Manufacturing on the Shop Floor: Hype, Reality, and Where It Actually Works, Ep #37

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Additive manufacturing has been “the future” of manufacturing for decades. And yet, for many shops, it still feels just out of reach—either too expensive, too complex, or too uncertain to justify. So where does it actually stand today?

In this episode of Lights Out, we sit down with Mark Barfoot, VP of Global Sales at Xact Metal, to cut through the noise. With more than two decades of experience in additive, Mark has seen the technology evolve from experimental curiosity to a legitimate production tool—and he brings a grounded, shop-floor perspective on what’s real versus what’s hype.

We explore where additive is delivering real value right now, starting with jigs, fixtures, and tooling, and how shops are using those applications as a gateway into more advanced production parts. Along the way, we unpack the biggest misconceptions—especially the idea that additive is simply a cheaper way to make the same parts—and why success starts with designing for the technology, not forcing it into existing workflows.

The conversation also dives into what it actually takes to bring metal additive into a machine shop—from facility requirements and safety considerations to the learning curve your team should expect. If you’ve ever wondered whether additive belongs in your shop (or how to even begin evaluating it), this episode gives you a clear, practical starting point.

Because the real question isn’t whether additive will replace traditional machining—it’s where the two work better together.

You will want to hear this episode if you are interested in…

(0:00) Real-world additive use cases including jigs, fixtures, and lightweight tooling
(2:19) Introducing Mark Barfoot and the current state of metal additive manufacturing
(6:54) Understanding additive hype cycles and why adoption takes time
(11:23) Why we created Hire MFG Leaders (and why you should use it)
(11:53) Why additive sticks: design freedom and enabling impossible geometries
(14:31) Designing for additive vs trying to replace traditional machining
(16:13) Where additive technology stands today across plastics and metals
(19:51) Production applications and additive adoption in job shops
(22:53) Justifying additive versus subtractive manufacturing
(24:35) An investment in ProShop ERP is an investment in your business
(26:10) Facility requirements for bringing metal additive into a machine shop
(32:45) Come see us at IMTS 2026!
(33:39) Resources that shop owners should dig into to learn more
(35:19) Common misconceptions about additive cost and capabilities
(38:09) How AI and topology optimization are shaping additive design
(41:57) Practical ways shops can start using additive internally
(46:04) Training, education, and building additive expertise in-house
(49:23) When additive makes sense and how shops should evaluate adoption