A recent Industrial Media poll asked manufacturing and engineering professionals a straightforward question: “What’s your biggest barrier to adopting new technology?” Out of four possible responses, 36% pointed to cost as the biggest hurdle. Legacy system integration followed closely at 33%, while workforce readiness accounted for 16%.
Industrial Media Poll ResultsIndustrial Media
The results underscore the many factors that influence technology adoption—and most companies aren’t held back by just one issue. Modernizing often involves navigating a complex blend of financial, technical and organizational challenges.
Technology expenses can come from both internal and external forces. According to a Microfab blog, external cost pressures include premium components, volatile pricing and ongoing supply chain disruptions. Rising prices in raw materials such as copper, gold and silver, combined with shifts in environmental and regulatory standards, have driven substantial cost increases. Add in volatile markets, higher component and shipping costs caused by logistical changes, global events, or labor shortages, and the result can be a project that simply isn’t financially feasible.
Internally, companies face skill shortages that limit their ability to implement or operate new technologies. Another Industrial Media poll highlighted how crucial skilled workers are to the successful adoption of advanced tools on the factory floor. A 2022 TD Shepherd blog on deep-tech startups notes additional internal costs: R&D, intellectual property protection, time-to-market considerations and processing expenses. Launching new technology often requires significant upfront investment on top of extensive engineering, testing and verification. The precision required in modern manufacturing amplifies these costs even further.
Beyond cost, legacy systems remain a major pain point for manufacturers. Many older systems rely on outdated technologies that are difficult to integrate with modern software. Especially while trying to maintain adequate security and vendor support. A BairesDev blog points out that companies heavily invested in maintaining older systems often stick with what they know. Transitioning to new platforms can feel risky, particularly when it requires learning unfamiliar tools.
Just as cost has major implications, so do the technical and operational challenges that legacy systems present. Compatibility issues, inefficiencies, security vulnerabilities and knowledge loss can all deter companies from pursuing upgrades, even when modernization could offer significant long-term advantages.
