Over the last few years, reshoring— bringing manufacturing back to the U.S.—has gained momentum, and not just due to tariffs or trade policies. Economic shifts, rising wages abroad, the pandemic’s supply chain disruptions, and national security concerns have created a perfect storm for executives to rethink their strategies.
For companies considering reshoring in the coming year, the challenges are real: redesigning products, rebuilding supply chains, and addressing workforce shortages. Modern technologies – such as digital twins, automation, and artificial Intelligence/ machine learning – offer powerful tools to not only overcome these hurdles but to make the transition a competitive advantage.
One of the first challenges of reshoring is that products originally designed for overseas manufacturing often aren’t optimized for the higher wages and automation requirements of U.S. production. By investing in technologies like AI and automation, companies can streamline production processes to reduce dependency on manual labor while improving precision and quality.
Virtual modeling tools such as digital twins allow companies to simulate production changes, identify inefficiencies, and validate improvements before implementing physical changes. This reduces risk, speeds up development, and positions companies to compete more effectively in high-cost environments.
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Another major hurdle when reshoring is rebuilding a supply chain that was previously dependent on overseas suppliers. Companies must source components domestically or integrate new suppliers, often while revalidating compatibility and quality standards. This is where technologies like digital twins become indispensable.
Digital twins provide a virtual representation of a company’s manufacturing or supply chain processes, enabling real-time testing and analysis.
By using these tools, companies can evaluate supplier options, simulate material substitutions, and optimize logistics strategies without interrupting existing operations. This not only helps reduce costly downtime but also ensures continuity and quality as supply chains transition.
The workforce challenge looms large for reshoring efforts. The U.S. manufacturing sector is already facing a skills gap, with millions of jobs going unfilled. For companies reshoring production, finding skilled workers—and upskilling their existing workforce—is critical. Technology again offers a way forward. At Boston Engineering, we’ve developed tools like Mixed Reality Expert Guidance (MREG) to address this issue.
MREG allows fewer experts to guide multiple workers remotely, magnifying their impact. For instance, instead of sending a senior engineer to every facility to troubleshoot issues, companies can use MREG to provide real-time video guidance securely, no matter the location. This not only saves time and cost but also enables companies to operate more efficiently despite workforce constraints.
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Reshoring is often viewed as a necessary response to external pressures, but it’s also a chance to innovate. By integrating technologies like AI, machine learning, and digital twins, companies can modernize not just their manufacturing processes but their entire approach to product development.
These technologies don’t just solve today’s problems—they position businesses for future success by building resilience and agility into operations. For example, companies that redesign products for automation and integrate real-time monitoring systems often see improved scalability, reduced costs, and enhanced product quality.
Such investments not only address current challenges but also enable companies to adapt more quickly to future disruptions or shifts in demand.
As we move further into 2025, reshoring will continue to be a critical priority for many companies. While the challenges are significant, they are not insurmountable—especially with the right technologies and expertise. At Boston Engineering, we’ve seen firsthand how tools like digital twins, AI, and automation can transform manufacturing and product development, enabling companies to navigate the complexities of reshoring with confidence.
For executives considering reshoring, my advice is this: Don’t just aim to bring production back—use this opportunity to rethink and reinvent. With the right technology and partners, you can build a supply chain and manufacturing process that’s not only more resilient but also more
competitive in the long term. Reshoring isn’t just about reacting to challenges; it’s about embracing the future of manufacturing.
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As the engineering landscape continues to evolve, Boston Engineering is committed to proactively integrating cutting-edge technologies and methodologies into the solutions it delivers, ensuring that clients stay at the forefront of industry trends and maintain a competitive edge in 2025 and beyond.
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For three decades, Boston Engineering has designed, developed, and optimized devices and technologies the medical community relies on to save lives, enrich quality of life, and reduce costs to the healthcare system. We provide solutions to the challenges in the adoption of surgical robotics.
Our expertise includes industrial design and product redesign, sensors and control systems, robotics technical innovation, and digital software solutions.
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