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Indirect Additive Manufacturing (AM)

Indirect Additive Manufacturing (AM) refers to workflows where the 3D printed part is not the final component, but an intermediate tool, mold, pattern or sacrificial structure used to manufacture the final object through secondary processes.

This approach combines the geometric freedom of additive manufacturing with the material performance of conventional manufacturing routes (e.g., metals, ceramics, elastomers or composites).

When indirect AM is the best route

  • When the final part must be made from metals, ceramics, elastomers or composites not suited for direct printing
  • When you need internal channels, undercuts, complex cavities or freeform geometries that are difficult to machine or demold
  • When surface quality, dimensional fidelity or downstream processing constraints are critical
  • When you want a repeatable workflow from R&D to production (print → process → remove pattern/mold)

Principle of indirect AM

In indirect AM, the printed object performs a functional role during processing—such as shaping, supporting, molding or patterning another material. After fulfilling its role, the printed part is removed (dissolved, broken away, burned out or otherwise eliminated), enabling complex geometries that are difficult or impossible to manufacture directly.

Types of indirect AM materials

Materials for indirect additive manufacturing are engineered to print reliably and perform predictably during secondary processing. Typical categories include:

Key requirements include dimensional stability, predictable thermal behavior, clean burnout or dissolution, surface quality and compatibility with downstream materials and processes.

Sacrificial and soluble materials

Sacrificial materials are designed to be selectively removed after processing. Removal can be achieved through thermal decomposition, solvent dissolution or water solubility, depending on the workflow.

They are widely used to create internal channels, undercuts, complex cavities and freeform geometries in casting, molding and composite manufacturing.

Easy-breakable sacrificial systems

Easy-breakable sacrificial systems (breakaway or “cocoon” concepts) are designed for fast removal after molding or casting, reducing post-processing time while preserving complex cavities and delicate features. See Easy Breakable Cocoon Sacrificial 3D Resins.

Castable materials

Castable 3D printing materials are used to produce patterns for investment casting. The printed pattern is embedded in a refractory mold and then burned out, leaving a precise cavity for metal, ceramic or other casting materials.

Controlled burnout behavior, minimal ash residue and dimensional fidelity are critical for high-quality final parts.

Mold and tooling applications

Indirect AM materials can be used to fabricate molds, inserts and tooling for silicone, polymers, composites and low-temperature processing. This enables rapid tooling, design iteration and complex mold geometries without the cost and lead time of traditional machining.

Injection in 3D printed molds (including powder feedstocks)

For ceramics, metals and functional composites, indirect workflows may use powder feedstock slurries injected into 3D printed molds. After shaping, parts can follow downstream steps such as debinding and sintering, depending on the material route.

Explore: Powder Feedstock Slurries for Injection in 3D Printed Molds

Advantages of indirect AM

  • Expands the range of achievable end-use materials and properties while retaining 3D design freedom
  • Enables performance routes that exceed the intrinsic limits of directly printable materials
  • Supports complex geometries and features that are challenging for direct AM or conventional tooling

Compatible technologies and processes

Indirect AM workflows can be combined with multiple additive manufacturing technologies, including vat photopolymerization, inkjet printing and selected powder-based routes. The best route depends on resolution requirements, part size, downstream material compatibility and post-processing constraints.

3Dresyns solutions for indirect AM

IFU & Printing Parameters

3Dresyns materials are process-dependent systems. Final performance depends on formulation version, printer technology, exposure strategy and post-processing workflow. Use our official guidance as your reference starting point in Instructions for Use (IFU) & Printing Parameters.

Need help selecting the right indirect route?

If you are unsure whether sacrificial molding, investment casting, injection/casting in printed molds, powder feedstock workflows or hybrid routes are best for your project, contact our technical team with your application, target material, geometry constraints and expected volumes at: info@3dresyns.com

Advanced 3D printing resins and technical expertise for medical, dental and industrial additive manufacturing