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The U.S. manufacturing supply chain sits at a critical junction. Geopolitical tensions, decades of offshore production, talent shortages, and the COVID-19 pandemic have converged to create systemic disruptions. These obstacles are especially pronounced for small- to medium-manufacturers (SMMs) within an evolving additive manufacturing (AM) industrial base. For these companies, financial and resource constraints coupled with education and workforce development (EWD) gaps hinder their ability to adopt and leverage the AM technologies to meet market need. As a result, SMMs risk falling behind in an increasingly competitive landscape.

Attracting and retaining talent was the primary business challenge indicated by more than 65% of respondents in the >NAM’s Manufacturers’ Outlook Survey for the first quarter of 2024. Given the integral role SMMs play in developing a robust supply chain, particularly within the Defense Industrial Base (DIB), their challenges pose a significant concern.

America Makes, the National Additive Manufacturing Innovation Institute, recognizes the urgent need for EWD initiatives. In response, the Institute collaborated with the Department of Defense (DoD) Office of Manufacturing Technology, the Massachusetts Technology Collaborative, the MIT Center for Additive and Digital Advanced Production Technologies, and the Massachusetts Manufacturing Extension Program to develop a detailed research report, “Preparing the Advanced Manufacturing Workforce: A Study of Occupation and Skills Demand in the 3D/Additive Manufacturing Industry.” This >report assessed EWD issues impacting SMMs, identified opportunities to mitigate these challenges, and outlined the learning assets needed to support AM integration into manufacturing operations.

Based on these findings and knowledge of the AM sector, focused, industry-grounded curriculums were defined and are now being deployed to help SMMs overcome talent and workforce barriers. By strengthening the foundation of these enterprises, the Institute has laid the groundwork for a robust talent pipeline to support the U.S. organic and defense industries, ensuring that the full potential of AM is realized.

Navigating AM talent and skills gaps

AM offers the potential to streamline processes, reduce costs, and provide greater design flexibility. However, fully realizing this potential requires a skilled workforce, particularly middle-skilled AM technicians, maintenance and support staff, and CNC operators – roles that demand extensive training and are increasingly difficult to fill.

To enhance the effectiveness of these technical workers, reports suggest training programs focused on quality testing and evaluation, computer interaction, decision-making and troubleshooting, specimen and equipment preparation, and improving communication and collaboration between engineering and management teams. For SMMs with limited capacity, developing effective hiring, training, and retention strategies remain cost-prohibitive, exacerbating the existing skills gap – an estimated 4.6 million unfilled positions in the market, according to the National Association of Manufacturers.

America Makes leverages a structured network of manufacturing partners, each bringing unique competencies to address industry challenges effectively. This collaborative approach has driven several joint initiatives aimed at meeting the specific manufacturing needs of various regions. By strategically aligning funding for capability development, the network ensures that knowledge is shared among local and regional partners, maximizing its impact.

As a direct result of these efforts, the Institute has launched high-impact programs, providing companies with essential curricula, content, and best practices to attract and retain the next-generation workforce. These initiatives support learners at every stage of their educational journey, from early awareness-building efforts to micro-learning modules spanning the entire AM process. This all-encompassing educational framework has culminated in comprehensive training and certification programs, ultimately assisting SMMs in expanding their talent pipeline and onboarding a more diverse workforce.

Key assets include:

• AMTrain: a curated state-of-the-art inventory of additive training assets intended to align KSAs (knowledge, skills, and abilities) to AM roles
• AMNation: an accessible platform housing America Makes EWD assets of practice-vetted microlearning modules and other engagement opportunities to expand the knowledge and skill sets of learners of all ages
• Drive AM: a robust digital engineering infrastructure solution and powerful training environment to meet elements of the DoD Strategies of the Digital Engineering Transformation.
• AM Jobs: a free digital tool to facilitate career exploration to a wide range of job roles in the AM industry
• Tooling U-SME: an exam-based program designed for entry-level technicians seeking essential AM knowledge to prepare for an apprenticeship program.

To date, America Makes has successfully engaged over 80,000 learners across 130 programs, collaborating with more than 100 K-12 and post-secondary institutions to expand their offerings. Additionally, the Institute has trained over 2,000 DoD personnel and veterans in its initiatives. For example, in partnership with Tooling U-SME, the Institute helped drive the deployment of 400,000 AM online courses to over 100,000 learners at more than 2,000 companies. This extensive reach underscores the significant role the Institute plays in shaping a skilled and innovative manufacturing workforce for the future.

Rebuilding SMMs, Strengthening the DIB

Investing in SMMs is imperative for securing a competitive advantage in the DIB and commercial markets. This investment attracts and retains a highly skilled workforce and drives modernization across production capabilities.

Considering the persistent challenges in workforce development, cultivating robust partnerships is vital for revitalizing the industrial supply chain. In collaboration with industry leaders and the DoD, America Makes is taking proactive steps to enhance workforce development by connecting students and adult learners with promising careers in AM. These strategic initiatives are essential for broadening access to skilled talent and empowering manufacturers to harness new business opportunities within the defense supply chain and beyond.

To learn more about the Institute’s EWD efforts, or how to participate, visit americamakes.us