Aibuild, based in London and Silicon Valley, develops AI-powered software for additive manufacturing. The platform combines additive and subtractive processes to make industrial production workflows more efficient and robust. Supported by machine learning and automated data analysis, Aibuild aims to improve the cost-effectiveness of large-scale applications. In an interview with 3Druck.com, Stefan Weyrich, VP Enterprise Sales EMEA at Aibuild explains how software-based process control has become a central component in industrial 3D printing and shares his outlook on upcoming developments.
The platform covers the entire digital workflow – from CAD geometry to the generation of precise toolpaths and their implementation on hardware. At the core is the automated planning of motion paths that print heads or robotic systems follow during the layer-by-layer construction of a part. Aibuild supports various large-format processes such as polymer extrusion, metal DED, WAAM, and concrete printing. AI-driven algorithms enable these toolpaths to be adjusted in real time to respond to changing process conditions – optimizing material flow, part quality, and process stability. The platform is available in both local and cloud-based configurations, supporting flexible, cross-location collaboration.
At its in-house Ailab in London, Aibuild tests new software capabilities under real production conditions. Various materials and hardware configurations are used to continuously refine the software and tailor it to specific industrial requirements. The company collaborates closely with partners in aerospace, automotive, construction, and energy to develop application-specific solutions.
With the launch of Aibuild 2.0, new features have been added, including an AI-based assistant to support new users, expanded integration with different hardware platforms, and an improved user interface. The goal is to enhance usability and further increase the level of automation throughout the additive manufacturing process.
Insights from Stefan Weyrich
In the interview with 3Druck.com, Stefan Weyrich discusses the growing importance of software in additive manufacturing and the role of intelligent process solutions in industrial applications. He offers insights into how companies can produce more economically and reliably through the use of digital tools.
In your opinion, what has changed most in AM software over the past ten years – and how has that impacted industrial 3D printing?
Stefan Weyrich, VP Enterprise Sales EMEA at Aibuild
Over the past decade, it’s become clear how significantly software has gained importance in additive manufacturing. In the early days, the focus was almost entirely on machines – hardware was everything. Then materials and applications came into greater focus. Only in recent years has software emerged as a central element – a clear sign of the AM industry’s growing maturity.
Previously, simply producing a part successfully was considered an achievement. Today, the question is: where does the competitive advantage lie when any company can manufacture the same part using identical parameters? This is where the value of modern software begins.
Design optimization, thermal simulation, automated support generation, or intelligent toolpath programming – these functions allow experts to directly influence the entire manufacturing process. This leads to real advantages, whether through reduced production time, lower material consumption, or improved part performance.
Software has evolved from a support tool to a strategic differentiator. Today, companies use software to build proprietary IP and gain technological independence and competitiveness.
What specific process or efficiency challenges do your customers typically face, and how do end-to-end software solutions like Aibuild help overcome them?
Our customers often face the challenge of producing complex, large-scale parts economically and reliably. Unlike smaller print applications, large-format additive manufacturing leaves little room for error – a failed print can result in days or even weeks of lost production time and significant material waste. In sectors like boatbuilding, where entire hulls are printed in just a few days, a single failure would be a major setback. Imagine a part failing after consuming several hundred kilograms of material and days of printing – it’s not just a time loss, but also financially unsustainable.
This is exactly where our software solution, Aibuild, comes into play. It is specifically designed to manage the complexity of large-format AM processes and make them easier, more efficient, and safer for users. Our platform enables fully integrated process planning – from the automated generation of toolpaths to real-time monitoring and optimization of print strategies.
Some of the key advantages for our customers include:
No material waste: Accurate simulations and automated checks help prevent costly failures and reduce material use to only what’s necessary.
Non-planar slicing: Our software supports printing in non-planar layers, improving mechanical performance and significantly reducing the need for support structures.
Accelerated production: Intelligent optimization tools and faster preparation workflows allow production times to be significantly shortened – without compromising quality.
End-to-end software solutions like Aibuild are a key enabler for advancing industrial additive manufacturing. They not only make processes reproducible and efficient, but also help companies position themselves technologically for the long term.
What role does the Ailab in London play in your innovation strategy, and how do customers and partners benefit from the insights gained there?
As a software company in the manufacturing industry, we’re particularly proud of our Ailab in London. It’s much more than just a development center – it’s where virtual concepts meet real-world manufacturing processes. Everything we develop is tested under actual production conditions. We don’t just write code – we’re in the workshop ourselves, working with machines, materials, and robotic systems – experiencing firsthand the challenges our customers face every day.
That’s what makes our software practical and resilient: we understand real-world requirements because we’ve lived them ourselves. This tight integration of software development and physical application is a core element of our innovation strategy. For over ten years, we’ve collected test data and conducted extensive R&D in the Ailab – with the clear goal of enabling our customers to achieve first-time-right production.
However, the Ailab in London is more than just a testing environment – it’s a place where customers and partners can experience firsthand how virtual development and physical manufacturing converge. Using state-of-the-art robotic systems for metal and polymer applications, we demonstrate how digital production works today. Visitors are often impressed by the lab’s capabilities and appreciate the practical insights that can be directly applied to their own operations. The Ailab thus serves not only as an innovation hub, but also as a space for collaboration, exchange, and inspiration.
What major trends do you see in the future of additive manufacturing, especially regarding the growing influence of artificial intelligence across the AM process?
One of the biggest current trends is large-format 3D printing with robotic systems. After years of development, this technology has reached a level of maturity – we’re seeing real end-use applications and the beginnings of serial production. What was once considered the “holy grail” of the AM industry is now becoming reality, as demonstrated by projects at BMW with Weber or Meltio in the defense sector. At Aibuild, we support a wide range of applications – from polymer extrusion using pellets or filament to metal DED, WAAM, and even concrete printing.
At the same time, we’re seeing a clear trend toward increased automation, with artificial intelligence playing a key role. Our software already enables the creation of automated workflows that significantly lower the barrier to entry for additive manufacturing. We are continuously working to make these features even more powerful and flexible. A major focus is our AI Agent, which helps new users get started, shortens the learning curve, and simplifies software interaction. Much like ChatGPT, the AI Agent will soon be able to answer many questions directly by drawing on extensive documentation – eliminating the need for time-consuming research. This saves users valuable time and allows them to focus more on optimizing their production processes.
For more information about Aibuild, visit their website.
Metal Binder Jetting: The Key to Efficient Tool Manufacturing? - Exclusive Insights from INDO-MIM
Fill out the form and get instant access to an exclusive webinar on HP's Metal Binder Jetting 3D printing technology with exciting insights from INDO-MIM.
Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
We use cookies to ensure that we give you the best experience on our website. If you continue to use this site we will assume that you are happy with it.OkRead more
