Siemens at Rapid + TCT 2025: What you missed and key takeaways

Rapid + TCT, North America’s largest additive manufacturing and industrial 3D printing event, recently concluded in Detroit from April 8–10, 2025, and it was nothing short of a success. This year, it came together with the AeroDef Manufacturing event to highlight the latest trends shaking up aerospace and defense manufacturing.

Siemens was front and center, showcasing cutting-edge digital additive solutions. Our software and hardware technologies also made their mark at partner booths. We connected with a wide range of stakeholders—those already using Siemens NX and those exploring its potential—and gathered valuable insights into the rapidly evolving world of additive manufacturing.

Looking to learn more? Dive into the key takeaways that are driving the future of manufacturing!

Advanced CAD and CAM integration streamlines toolpath planning

Tool path planning in CAM (Computer-aided manufacturing) often requires CAD (computer-aided design) functionality to be effective. Whether creating supplemental check bodies for path avoidance areas, creating boundaries to contain or drive the tool path with, or redesigning a part for additive manufacturing, CAM programmers must have at least some basic modeling functions to complete their tool path strategy for a given part.

The most efficient programmers are those with the full set of CAD tools integrated within the same software used for CAM. This was emphasized at the Rapid + TCT event, where the importance of CAD tools for AM build preparation was made clear by numerous AM solution providers.

All-in-One platform for CAD, CAM and AM

Discussions at Rapid + TCT emphasized the critical need for integrated design and manufacturing capabilities in additive build preparation. Several AM (additive manufacturing) solution providers shared how segregated CAD and CAM tools lead to inefficient workflows. One company evaluating Siemens NX for robotic wire directed energy deposition (DED) explained how they currently decompose designed parts in a separate CAD system, then import the models into CAM software to create additive tool paths.

The challenge arises when build planning reveals the need to modify additive features. Because the CAD and CAM tools are disconnected, the company must return to the CAD system, redo the decomposition, and re-import the model—often with no assurance that existing paths will still work. In many cases, this forces them to scrap the entire AM build plan and start from scratch.

With Siemens NX, these challenges are eliminated. CAD, CAM, and AM functions are fully integrated, allowing users to decompose part bodies, edit features, and continue build planning within the same environment. Tool paths automatically update with design changes, reducing the risk of rework. Programmers can also incorporate machine-specific components like clamps and build plates to create a true digital twin of the build environment—enabling precise path planning and collision checking from the start. This level of integration supports faster iteration, greater process stability, and fewer disruptions in AM production planning.

Digital Twin ensures accurate build simulations

An integrated platform goes beyond convenience — it enables smarter build simulation. With CAD and CAM tools working together in NX, decomposing a part body for additive tool path planning — and making changes during build preparation — is seamless.

Existing tool paths remain intact, allowing continued progress without disruption. Assembly modeling capabilities make it possible to include machine components like clamps and build plates, creating a digital twin of the build setup. This gives programmers the confidence that their strategy will work as intended, minimizing the risk of gouges or crashes.

Composite Tooling requires precise sub-structures

At Rapid + TCT, alongside AeroDef Manufacturing, the spotlight was on the growing demand for composite tooling—especially for aerospace and defense applications that rely on carbon fiber layup tools. A critical design element in such tooling is the sub-structure beneath the mold faces. These internal features provide stability during production, particularly in autoclave processes where heating and vacuum forming occur under pressure.

Despite appearing simple, sub-structure design presents several challenges. Not only must these supports maintain minimal contact with the mold faces to allow maximum airflow, but they must also avoid interference with additional hardware used for vacuum forming. This hardware is often fastened directly beneath the mold faces, in the same space as the sub-structures, meaning designers must allow just enough clearance for toolmakers to assemble all components without conflict.

These tight constraints make a strong case for using integrated design software that combines additive and subtractive manufacturing workflows. When CAD and AM tools operate in a single environment, engineers can respond to tool path planning insights and update designs without starting over. In contrast, switching between separate systems increases the risk of error and the potential for costly scrap— especially in large-scale composite builds.

Additive + subtractive + hybrid machining = end-to-end solution for part manufacturing

When working with composite tooling, a hybrid machining approach is essential. Additive and subtractive manufacturing, along with hybrid machining, provide a comprehensive end-to-end part manufacturing solution. 3D-printed parts require subtractive machining for the best surface finish, which involves 2-1/2 axis, 3-axis, and 5-axis cutting strategies.

Similarly, metal 3D printed parts require precise machining for their mating faces. The integration of both additive and subtractive manufacturing within the same software creates a seamless, efficient solution, eliminating the need to switch between different platforms. With all of these capabilities, NX delivers a comprehensive hybrid machining solution.

The future of an end-to-end part manufacturing solution

Rapid + TCT showcased the latest advancements in additive manufacturing, and adding AeroDef Manufacturing to the show reminds attendees of the importance of considering end-to-end solutions.  Manufacturing is hardly ever a linear process; it begins with design, and it often needs adjustments along the way. The best solution is when all the required design, additive, and CAM capabilities are packaged together for a seamless workflow, and Siemens NX is just the right product.