Hybrid Nesting Optimization in PBF 3D Printing: Enhancing Prototyping Efficiency and Circular Material Use

This case study presents the optimisation of powder bed fusion (PBF) additive manufacturing at TECHNOLOGY APPLIED, achieved through the introduction of a hybrid nesting method and improved material circularity. By combining automated algorithms with operator expertise, the company was able to increase packing density from 5–8% to 14–16%, stabilise the thermal behaviour of builds and reduce the risk of deformation and unit costs. Concurrently, raising the proportion of recycled PA12powder from 50% toward a 70% target strengthened circular economy and reduced material waste. These results demonstrate that progress in additive manufacturing requires not only technological improvements but the development of interdisciplinary competencies aligned with Industry 5.0. These competencies include resilience, digital skills, and environmental awareness. The recommendations outlined here emphasise ecological transformation, competency development, knowledge sharing, and a holistic, human-centred technological approach. This forms a foundation for further efficiency gainsand sustainable competitiveness.