3D printing has been widely used in the aerospace sector to manufacture aerospace components that are more dependent on aesthetics instead of functions. These include door handles, light housings, and full interior dashboard designs. 3D printing is also used to manufacture metal brackets that often perform a structural function inside aircraft. Over the years, increasing number of prototypes have been 3D printed which have enabled designers to enhance the form and refine fit of the finished parts. 3D printing in aerospace sectors have enabled efficient production of interior aircraft components such as cockpit dashboards and door handles. Additive manufacturing technologies have been used for prototyping, repair and maintenance, and for producing parts and components. 3D printing has also been used for jigs, fixtures, and tooling or bridge production. With constant advancements in 3D printing, use cases of this technology are expected to increase dramatically in the aerospace, space, and defense sector.

3D printing has been applied in almost all the stages of the design workflow for applications in the aerospace industry such as in design communication wherein 3D printing is used to create concept models that showcase a new component of aircraft and is also regularly used for aerodynamic testing that plays a crucial role in aerospace industry. Prototyping using 3D printing helps develop products that are low-cost and can be used to produce low to medium runs of parts. 3D printing in aerospace also allows for customization of aerospace components that are highly complex to improve aircraft performance. 3D printed components reduce weight of the aircraft, minimize fuel costs significantly, and provide consolidation and topology optimization of many custom aerospace components. Over the years, more and more companies have developed newer technologies and materials for aerospace 3D printing.

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In April 2022, National Aeronautics and Space Administration (NASA) announced development of all-new metal 3D printing allow that has been specifically designed for use in high-performance aerospace systems. GRX-810 is an example of an oxide dispersion strengthened alloy and the material can reportedly withstand very high temperatures such as above 1090 °C. NASA plans to utilize this material to 3D print high-temperature components for systems including rocket engines as it can improve fuel efficiency and lower maintenance costs. In addition, in a recent breakthrough research study published in May 2022, a team of researchers led by the University of Glasgow developed a 3D printable carbon nanotube-based plastic material that can sense its own structural health. This material has the potential to find new applications in automotive and aerospace design wherein low-density, tough materials having self-sensing capabilities are extremely desirable.

Major companies in the aerospace 3D Printing market include Stratasys Ltd., Höganäs AB, EOS GmbH, Norsk Titanium AS, MTU Aero Engines AG, 3D Systems Corporation, Materialise NV, Ultimaker BV, EnvisionTEC GmbH, and ExOne. In May 2022, EOS announced a strategic partnership with Hyperganic, which is a prominent player in engineering design software, to improve design and performance of 3D printed aerospace components. Under the partnership, the companies will be integrating Hyperganic Core, which is the AI-based algorithmic engineering software of Hyperganic, into laser powder bed fusion 3D printers developed by EOS. This will allow EOD customers to design their space propulsion components by leveraging algorithmic models and this transition is expected to further streamline the design workflow and accelerate development of components with correct geometries and optimal performance efficiency.