We are at the precipice of a new era in manufacturing. In today’s ever-changing world, one thing has become abundantly clear: the only way forward is to evolve.
Geopolitics Garner International Trade Tensions
Manufacturing has undergone tremendous changes over the past hundred years. History shows us that those who prevail are the ones willing to adapt their practices to meet new demands. Starting in the late 1970s, many North American manufacturers began outsourcing goods and raw materials to cut costs and improve profit margins, driven largely by competition with lower-cost labor overseas. Today, although skilled workers in North America earn competitive wages, manufacturers still struggle to fill critical skill gaps.
As a result, traditional manufacturing methods have become less profitable and increasingly challenging to sustain—making it harder for companies to not only survive but also grow in this changing landscape.
In today’s geopolitical climate, North American manufacturers have faced repeated setbacks—most notably in the steel and aluminum sectors. With American tariffs in constant flux, deep and unpredictable uncertainty has become the new normal. This instability directly affects manufacturers’ bottom lines.
Steel and Aluminum Tariffs Doubling June, 2025
Steel and aluminum remain foundational materials in industrial manufacturing. Steel is typically used for structural components, infrastructure, and heavy machinery, while aluminum is preferred for its lightweight strength—ideal for automotive, machinery parts, construction, and aerospace applications.
It’s widely recognized that the current geopolitical environment is not conducive to predictable business planning. Yet manufacturers continue to depend on these raw materials to keep operations running. Many feel stuck—caught between escalating trade tensions and skyrocketing import costs—leading to a crucial question: “What is the viable alternative to metal in modern manufacturing?”
Enter: polymers.
Can Manufacturers Replace Metals with 3D Printed Parts?
Polymers may not be new, but their role in advanced manufacturing is evolving rapidly. At their most basic, polymers are materials made from long chains of repeating molecular units. But in the right formulations, they become more than just plastics—they become engineered, high-performance alternatives to metal.
High-performance polymers like PEEK (polyether ether ketone) and PEKK (polyether ketone ketone) are at the forefront of this transformation. These aren’t your everyday plastics; they are high-temperature, high-strength thermoplastics that can, in many cases, rival the mechanical performance of metals like aluminum and even steel.
PEEK and PEKK are prized for their exceptional strength-to-weight ratio, chemical resistance, and thermal stability—with some grades capable of withstanding continuous use at temperatures over 250°C (480°F). They offer superior durability, wear resistance, and low friction, making them ideal for demanding, high-performance applications.
Alongside these, other advanced polymers such as carbon fiber-reinforced nylon (CF-Nylon) provide excellent alternatives to steel and aluminum, delivering strength and rigidity with added flexibility. From aerospace components to automotive parts, medical devices to energy systems, these engineered polymers are increasingly replacing metals in critical applications.
The Advancement of Polymer Parts in Manufacturing
What sets them apart isn’t just performance—it’s processability and adaptability. Unlike metals, these engineering-grade polymers can be molded into complex geometries with minimal waste, enabling faster prototyping and more efficient production.
They also contribute to weight reduction, which directly translates into energy savings and lower emissions—especially critical in transportation and aerospace industries.
For example, A high-performance bright steel bracket commonly used in aerospace might weigh around 2 kg. While the raw steel material is relatively inexpensive (approximately $1–2 per kg), the total cost per bracket—including machining, finishing, quality certification, overhead, international shipping, and potential tariffs—can easily reach $150 or more. [source]
PEEK has become a popular lightweight alternative in aircraft brackets. For example: Airbus replaced aluminum door-bracket fittings with a carbon-fiber–reinforced PEEK bracket for the A‑350, achieving 40% reductions in both weight and cost. [source]
In contrast, a polymer alternative made from PEEK can weigh less than 700 grams—reducing weight by over 65%—while maintaining comparable strength and thermal resistance. A single spool of PEEK filament costing approximately $600 can produce dozens of such parts, drastically lowering material costs and eliminating many supply chain risks.
This weight reduction is critical in industries like aerospace and automotive, where every gram saved translates to improved fuel efficiency and lower emissions. Moreover, polymers allow for design innovations impossible with metals—integrating internal channels, complex lattices, and consolidated assemblies in a single print—reducing the number of components and assembly steps.
The Benefits of Manufacturing with Polymer Parts
These advanced polymer composites offer a compelling set of advantages that make them a viable metal replacement, including:
As well as significant cost and manufacturing advantages such as:
These properties make 3D printed polymers ideal for high-performance applications across aerospace, automotive, industrial, and consumer sectors.
For a deeper dive, explore our comprehensive guide, "How to Deploy Additive Manufacturing into Your Supply Chain Strategy", which outlines how to successfully integrate scalable 3D printing solutions into your manufacturing operations.
Reshore Production by Integrating Automation into Polymer Part Manufacturing
As manufacturers search for materials that can withstand extreme conditions without the volatility of global metal markets, the question is no longer if polymers can compete—but how to get started.
That’s where we come in.
At Mosaic, we specialize in unlocking the full potential of advanced polymer and composite materials. Our cutting-edge automated additive manufacturing technology enables rapid prototyping and production of composite parts with unmatched precision and performance.
By integrating automation, companies can move production closer to home—reshoring or nearshoring operations to reduce dependence on distant suppliers and volatile global supply chains. This not only mitigates risk but also offers a path to bypass tariffs and other costs associated with overseas manufacturing. Our solutions empower businesses to bring production in-house, avoiding the need for high-cost skilled labor and reducing logistical complexity.
Whether you're looking to replace metal components, reduce weight, or scale up production without the overhead of traditional tooling, Mosaic provides the tools and expertise to transform your supply chain and manufacturing strategy.
Ready to take your designs further?
Contact us today to get started and discover how Mosaic can help bring your high-performance parts to life.