Additive manufacturing, popularly known as 3D printing, is a process where materials are layered through computer control to build an object from a digital file. In North America, this has proven quite beneficial for parts production and prototyping, particularly in the automotive, aerospace and medical industries.

In the lighting industry, 3D printing continues to show strong promise, because speed to market is essential. Product diversification with specialized functionality and smaller volumes has become prevalent and supply chains are geographically extensive. 3D printing addresses pain points in each of these areas, combining customization with rapid local production and enhanced sustainability.

At its core, all that is needed is a digital design file and access to raw materials and a printer. Designers can create distinct designs for prototyping, testing and eventual production. Customization and modification are more accessible. From there, cost-effective, on-demand production becomes possible, with no extraordinary upfront investments in tooling and inventory; someone is able to order a single item with potentially shorter lead times.

Notably, production can occur anywhere there is a printer, shrinking the supply chain to the local level. Imagine luminaires printed at a nearby electrical distributor, print shop or even crowd-sourced. This aspect is still, to an extent, theoretical, as current laws and regulations do not favor it. For maintenance, however, replacement of luminaires or certain components could be as simple as printing one-offs from a digital file, meaning they are always available.

The first application in the lighting industry was prototyping. Since then, the technology developed to enable complete customized luminaires, with various companies using it. A leader has been Netherlands-based Signify, notably its Genlyte Solutions and Cooper Lighting Solutions professional business units. In the last seven years, the company has 3D-printed about 3.5 million luminaires for the global market, according to the company.

How does Signify do it? The lighting practitioner creates the luminaire using an online configurator with basic specifications including form factor; integrated or lamp-based; colors and textures; and functional details including lumens, beam angles and color temperature (a color rendering index rating of 90 is standard). 

The resulting G-code, or digital design, is fed to deposition modeling printers specifically designed to produce large-format, high-precision lighting components. These printers produce the luminaire layer by layer using 75% recyclable or bio-based materials and waste such as water jugs. In the United States, the luminaires are DLC Premium listed, ISCC-certified, carry Red List-approved Declare labeling and are Buy American Act-compliant.

For prototyping, the process can take weeks instead of months, according to Signify. For high levels of customization or volumes, the company maintains a team of specialists to support projects.

Applicable to ECs

“3D printing can solve real-world problems for electrical contractors by offering speed, flexibility and customization that traditional manufacturing can’t match,” said Tony Costa, product marketing manager, 3D printing at Signify. “It offers fast lead times and replacements with rapid on-demand production.”

Where do electrical contractors fit into this? Costa pointed to situations where standard luminaires do not fit unusual ceiling types, retrofit openings or architectural details. In these situations, 3D printing enables precise customization to match challenging site conditions without costly redesigns. It also offers the possibility of using recycled and bio-circular raw materials for the luminaires, which can help meet LEED and WELL building program and customer environmental, social and governance objectives.

Where custom luminaires are developed using 3D printing, a sampling of luminaires could be printed and installed, giving the design team the chance to modify the design and associated digital files. 

Once approved, the contractor might maintain a record of the digital file to offer a source of replacements for future maintenance needs.

Otherwise, the 3D-printed luminaire should function similarly to a traditional luminaire from an electrical and safety standpoint, as long as it is UL-, ETL- or CSA-listed and meets NEC requirements.

“In essence, electrical contractors don’t need to be experts in 3D printing itself,” Costa said. “But they do not need to confirm that the products meet all applicable codes, listings and installation standards to ensure safety, reliability and compliance on every job.”

3D printing has changed prototyping and custom lighting, and it offers the potential to transform maintenance and even lighting supply chains. This makes it a technology to watch in the future.

“3D printing has fundamentally changed what’s possible—not just in design but in how we think about manufacturing, sustainability and supply chains,” Costa said. “3D printing enables luminaires to be produced locally, on demand and from recycled or bio-based materials, drastically cutting waste and emissions while offering unprecedented design freedom. It’s not a niche innovation—it’s a scalable, circular manufacturing model that aligns with the lighting industry’s future. It’s more adaptive, more sustainable and more responsive to customer needs.”

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