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Again in 2013, I keep in mind being utterly blown away when an organization known as Strong Ideas reportedly additively manufactured almost a whole firearm as a proof of idea. Though desktop polymer 3D printers had already been making headlines round the potential of unlawful manufacturing of unserialized “firearms” (which actually resembled extra of an explosive system powered by conventional small arms cartridges), this was the primary time a authentic contract producer had utilized steel additive manufacturing to make an precise serialized, authorized firearm. So far as may be remembered, they produced many of the precise elements through AM as a proof of idea, however definitely different manufacturing processes have been concerned as they might at all times must be in producing an enthusiast-quality firearm.
Lately, coming house from the SHOT Present in Las Vegas—one of many largest international small arms and taking pictures sports activities reveals in the complete world—it’s outstanding to have a look at the place the additive {industry} has come on this house.
There have been simply two dozen additive manufacturing-related firms within the present’s Provider Showcase this 12 months, essentially the most I can ever recall seeing. And that is no shock, given the final eighteen months of innovation and explosive development within the space of small arms silencers—basically what’s a muffler for a firearm. And whereas sure, there was a cross part show pattern of a 3D printed steel suppressor on principally each AM firm’s tabletop on this space of the present, there’s really much more to the adoption of powder steel manufacturing tech on this house that AM stakeholders may wish to pay attention to.
Functions, Supplies, Processes, and Enterprise Mannequin Improvements
Despite the fact that I’ve simply stated there’s extra than simply silencers to concentrate to on the earth of small arms, I ought to begin off by being clear on this space. Small arms silencers shall be to steel powder AM applied sciences what the dental and jewellery industries mixed are to photopolymer AM applied sciences. I’m not simply speaking about promoting some printers, however about transferring the dynamics of the complete steel powder {industry}. This software is impacting additive in a similar way to the best way that rocket engines did the final 4 years or so.
Silencers made through steel additive are the entry level for a lot of. Nonetheless, the SHOT Present this 12 months highlighted the concept there are additionally extra functions to discover within the space of small arms. It’s notable to level out the adoption of one other non-additive steel forming course of, which nonetheless is technically the king of the world of small arms: steel injection molding (MIM). On the planet of MIM, firearms are certainly one of three clear industry-leading functions throughout the globe.
Why will we, the additive {industry}, care about MIM’s function in small arms? First, we will get some concept of the potential software map for additive applied sciences on this house past silencers. Smaller, much less geometrically complicated elements for firearms (reminiscent of launch levers, muzzle breaks, locking pins, and many others) aren’t at all times the primary thought for AM. Nonetheless, within the space of small arms, customized and low quantity/excessive worth have turn into a big driver of the boutique facet of the {industry}. Mixed with AM’s fast capability to manufacture with supplies like titanium or stainless-steel alike, we will see how MIM has supplied the blueprints for AM to play off of—not essentially for important volumes of the identical elements, however for smaller volumes and a excessive mixture of customized elements.
New functions for each MIM and AM are additionally rising within the house and have been on show at SHOT Present. Magpul’s sales space confirmed MIM knife tangs and blades, making for a powerful showcase of the know-how. In the meantime, AM is concurrently being explored for direct printing of a whole knife meeting together with metallic grips and blades, one thing which was proven by One Click on Steel at formnext 2025 a couple of months in the past.
However perhaps a very powerful profit AM can carry from silencers into the broader small arms house is the facet of enterprise mannequin innovation. During the last two years, a large number of boutique silencer firms have been in a position to launch quickly leveraging software program and design abilities instantly into product realization with a transparent advertising message and (typically) a reliable worth proposition. Not all have been in a position to execute in addition to others, however typically talking, AM has actually energized the silencer house into its most fun time in historical past. It might feasibly do one thing comparable for the remainder of the small arms house by enabling boutique and fanatic merchandise that wouldn’t be possible in any other case.
On the present ground, I noticed polymer additive all over the place as nicely. HP’s Multi Jet Fusion has been adopted as a producing course of for accent gadgets by small improvement firms for the final 4 years, printing issues like housings for stress pads, covers and anti reflection units for electro-optics, and even whole housings for night time imaginative and prescient goggles. Within the night time imaginative and prescient sector, we noticed not simply sintered buttons for controls on goggles, however even titanium printed swing arms and different steel elements.
AM Silencers Quickly Evolving with Development, Challenges, and Options
SHOT Present 2026 was the one largest assortment of AM silencer exercise that’s ever existed, evidenced by cubicles from powder suppliers, AM machine firms, outsourced manufacturing companions, and suppliers of ending providers.
The U.S. civilian silencer market grew 31 % in simply 2025 alone, in line with new information from the Bureau of Alcohol, Tobacco, Firearms and Explosives (ATF).
This was even earlier than the most recent regulatory change that went into have an effect on on January 1st, 2026, which eradicated the financial tax related to the applying and approval course of for silencer buying. It has already been reported by the American Suppressor Affiliation that on January 1st, the ATF E-Varieties system processed roughly 60 instances the standard each day demand for kinds.
We will count on near a doubling of development within the U.S. shopper silencer market in 2026. Practically 750,000 new silencers have been bought in 2025 (a 31 % development in whole registered silencers), and with 125,000 possession software kinds processed on simply the primary day of 2026, it’s seemingly over 1,000,000 shall be bought this 12 months. It doesn’t take greater than strolling across the SHOT Present ground to grasp simply what share of these are more likely to be additively manufactured. That is the most important development alternative the {industry} has ever skilled.
Nonetheless, all that development shouldn’t be with out challenges and adjustments. The impacts in powder demand to assist this development are important, with big volumes of powder now being shipped to assist it. One outsourced print providers supplier who performs a notable function in printing silencers indicated they order 2 tons of titanium powder per thirty days (and that doesn’t even account for the Inconel silencers they make). Nonetheless, all of this exercise has quickly deteriorated powder margins, virtually out of nowhere. Powder producers are pleased to have their investments in capability now being paid for, however profitability is now troublesome.
New options within the silencer market are additionally being introduced—an anticipated end result of a lot exercise. HP specifically confirmed off a few of its steel binder jetting capabilities within the context of silencers, touting considerably decrease prices per unit resulting from higher productiveness within the course of. This could possibly be welcome information to the silencer market, which can now additionally face important margin stress. Printed silencers are transferring from boutique, high-value innovation on a quick monitor in the direction of commodity gadgets due to the explosion in demand. Nonetheless, there are nonetheless loads of alternatives to construct an enduring model and product on this space that stands out, even amongst the swell of recent AM merchandise on this market.
Supply: AM Analysis
The Way forward for Superior Powder Steel Manufacturing Applied sciences in Small Arms
The long run for each MIM and AM powder-based superior manufacturing strategies is a little bit of a combined bag as we speak. The general firearms {industry} has been notably down the final two years, which has impacted total demand for brand spanking new firearm orders and elements and thus affected the MIM {industry}. Nonetheless, MIM continues to evolve in makes an attempt to realize share of elements which could in any other case have been machined, and will increase partly measurement and materials capabilities will hold pushing MIM ahead. As well as, the co-adoption of additive manufacturing applied sciences, together with each powder mattress fusion and binder jetting, alongside MIM as a one-two punch for superior manufacturing is believed to be a internet profit for MIM.
For AM applied sciences like powder mattress fusion in each polymers and metals, and in addition extra lately binder jetting and UV photopolymerization, there’s important development forward. Most of that is concentrated in silencer manufacturing, however as identified within the preliminary part and reviewing the SHOT Present 2026 exhibition, there are clearly extra functions in small arms. The AM {industry} wants to grasp that that is being pushed by the business market. The U.S. army has a significant function in influencing the business market, however the quantity of elements is considerably and more and more bigger every year on the business facet. Navy contracts may be helpful, however they solely characterize about 3 to five % of whole silencers bought every year.
At current, the main target of stakeholders on this space who wish to broaden from the more and more crowded silencer market ought to give attention to growing a model to assist enterprise mannequin innovation on this house. That’s as a result of the market surroundings is favorable for a lot of these fanatic and boutique merchandise—most of which may be served by additive manufacturing.
To study extra, learn the AM Analysis “Additive Manufacturing of Firearm Silencers: 2026 Market Replace,” meant to complement our 2024 market examine.
Scott Dunham is Government Vice President of Analysis at AM Analysis. He has authored dozens of in-depth market analysis research on varied elements of the 3D printing {industry}, giving him one of many widest views on the know-how on the earth. He has spoken at many prestigious occasions and is often consulted and cited by {industry} main firms.
At Additive Manufacturing Methods 2026, he’ll current “20(/)30 Imaginative and prescient: Market Knowledge” on February twenty fourth, “Dental AM Market Forecast” on February twenty fifth, and “Panel: 3DP/AM Market Knowledge and Outlook” and “AM Functions Knowledge” on February twenty sixth. You’ll be able to register for the occasion right here.
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