Protolabs is significantly expanding its metal 3D printing capacity in the United States. The background is rising demand for additively manufactured metal components, particularly from the medical technology, aerospace and defense industries. In 2025, the company has, by its own account, invested both in additional machines and in certifications in order to be able to cover more end-use parts in series production.
The core of the expansion is a new plant in Raleigh, North Carolina, which is dedicated entirely to Direct Metal Laser Sintering (DMLS). The facility, with around 120,000 square feet of floor space, houses nearly 40 DMLS systems and is designed for more than 8,000 metal parts per month. Recent investments include four large-format, dual-laser Colibrium Additive M2 systems. The machines are suitable for fine, weight-optimized structures and thus target typical use cases such as implant components, lightweight brackets or thermally stressed add-on parts made from nickel and cobalt superalloys as well as tool steels.
In parallel with the technical upgrade, Protolabs has reinforced the regulatory side. The DMLS plant now holds ISO 13485 certification for medical products, complemented by AS9100D approval for aerospace applications.
“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.”
“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.
With the expanded DMLS fleet, Protolabs also aims to establish new materials, process chains and secondary operations so that designers can exploit the design freedom and lightweight potential of metal 3D printing without having to compromise on dimensional accuracy, surface quality and documentation for series production.
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