Protolabs is responding to the growing demand for additively manufactured metal components and has significantly expanded its capacities in the USA in 2025. The focus is on a new site in Raleigh, North Carolina, which is fully dedicated to Direct Metal Laser Sintering (DMLS). Four large-format, dual-laser Colibrium Additive M2 systems were recently commissioned there to manufacture complex metal components for industries such as medical technology, aerospace and defense.
The new facility, with around 120,000 square feet of floor space and nearly 40 DMLS systems, is among the larger metal AM factories in the United States. Protolabs states a capacity of more than 8,000 parts per month. The M2 systems are designed to reliably produce delicate lattice structures, internal channels and lightweight-optimized geometries. For many customers, the focus is no longer solely on functional prototypes, but increasingly on series and end-use parts that require defined material properties and reproducible quality.
In parallel with the capacity expansion, Protolabs has made targeted investments in certifications. The DMLS site in Raleigh is certified to ISO 13485 for medical products as well as AS9100D for aerospace applications. These standards address topics such as traceability, process documentation and risk management – key prerequisites for using additively manufactured components in regulated markets.
“Protolabs’ comprehensive additive manufacturing capabilities have made us the preferred partner for 3D‑printed parts in the U.S,” said Suresh Krishna, President and CEO of Protolabs. “We’re sustaining our lead by listening to our customers and responding by investing in technologies that will continue to drive innovation.”
At a recently held on-site event, representatives from the medical technology and aerospace sectors discussed process chains, secondary operations and engineering support with Protolabs’ AM specialists.
“Fundamentally, Protolabs’ 3D printing capacity, expertise, and reputation for speed and quality offer a compelling combination for businesses in these sectors, whether it be rapid prototyping or final production,” said Kenny Capps, director of 3D printing manufacturing operations.
The expansion in Raleigh shows how metal 3D printing is increasingly integrating into industrial series processes. Users can take advantage of design freedom and lightweight potential without having to compromise on quality assurance, documentation and delivery performance – a prerequisite for additive manufacturing to continue gaining importance in critical applications.
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