US Manufacturers Are Accelerating Reshoring, But Most Lack the In-House Capacity to Keep Up

Why It Matters

Reshoring promises greater supply‑chain resilience for U.S. manufacturers, but the capability gap could delay those benefits and spur demand for advanced additive‑manufacturing technologies.

Key Takeaways

• 30% reshored production; 49% still transitioning.
• Only 34% say in‑house capacity fully adequate.
• 73% increased capital‑equipment budgets; 22% >20% rise.
• Skilled staff shortage and integration time hinder reshoring.

Pulse Analysis

The push to bring production back to U.S. soil has intensified as tariffs and trade‑policy volatility force manufacturers to reassess offshore dependencies. The BigRep survey confirms that reshoring intent is now near‑universal, with three‑quarters of large firms either having reshored or actively planning to do so. This shift aligns with broader economic goals of strengthening domestic supply chains and reducing geopolitical risk, but the speed of strategic decisions is outpacing the readiness of existing manufacturing infrastructure.

A critical bottleneck emerges in the form of insufficient in‑house capacity. While 73% of respondents report larger capital‑equipment budgets, only a third feel fully equipped to handle disruptions, and more than half rate their capabilities as merely partial. The primary obstacles are not just financial—equipment costs, lengthy integration timelines, and a shortage of skilled operators all impede rapid scaling. These constraints highlight a structural skills gap that could slow the overall reshoring momentum unless addressed through targeted workforce development and technology adoption.

Additive manufacturing, particularly large‑format FFF 3D printing, offers a pragmatic bridge for firms caught between strategic intent and operational reality. BigRep’s new ONE.5X, DRYCON, and VIIO 250 printers promise higher throughput and flexibility, enabling manufacturers to produce complex, high‑volume parts without the extensive retooling required by traditional equipment. By showcasing these solutions at RAPID + TCT 2026, BigRep positions itself as a catalyst for the next phase of domestic production, where rapid, on‑demand manufacturing can mitigate supply‑chain risks and accelerate time‑to‑market for U.S. companies.