Additive Snack

Imagine printing a car part for the racing industry as your first additive manufacturing (AM) project, earning a process engineer position with Honda Aerospace, and following that up by becoming the AM technology leader at Ohio State University. This is the inspiring story of today’s guest. 

Joining host Fabian Alefeld is Ben DiMarco, AM Technology Leader and Principal Engineer at Ohio State University’s Center for Design and Manufacturing Excellence (CDME). In this conversation, they explore Ben’s contributions to lattice structures, process monitoring, and innovative technologies such as nLIGHT and cold metal fusion. They also touch on Ben’s role and passion for workforce development. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[1:15] In 2009, Ben’s first printed AM part was a brake fluid reservoir used in the racing industry. 

[3:39] Ben describes the key characteristics of lattice structure and its impact on part performance. 

[8:18] For the past few years, Ben’s objective has been to create a semi-empirical model for lattice structures. 

[17:03] Ben’s vision for how his work will impact the AM industry. 

[22:03] An overview of nLIGHT technology and OSU’s beam shaping project. 

[32:14] Examples of current and future uses of artificial intelligence in additive manufacturing. 

[34:47] OSU’s forthcoming study includes the history and future of cold metal fusion. 

[39:21] Ben explains OSU’s CDME workforce development program. 

It is common to hear about productivity, materials, and laser power in additive manufacturing (AM). But stories are rarely heard about the lives being changed because of this technology. Innovation in AM is not just about technology. It is about transforming lives and creating a better future for people. 

Host Fabian Alefeld speaks with Princess Moshoana, a South African woman whose life was forever changed by a violent act and then restored through the marvels of AM and Dr. Gerrie Booysen, a leading figure in AM and Director of the Centre for Rapid Prototyping and Manufacturing at the Central University of Technology. Together, they share a journey of recovery and groundbreaking advancements in medical industrial 3D printing. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

 
[1:31] Princess recounts the violent crime that left her physically and emotionally unable to smile. 

[7:11] Dr. Gerrie Booysen explains the history of the Centre for Rapid Prototyping and how they began 3D-printed patient-specific implants. 

[11:06] The arduous process chain of creating, implanting, and reconstructing Princess’ jaw with an AM printed part. 

[13:37] How additive manufacturing helped Princess regain her hopes and dreams. 

[15:14] The many ways AM devices and reconstructive surgery can meet the tremendous needs of South Africans. 

Resource Link:  Centre for Rapid Prototyping and Manufacturing 

The world of additive manufacturing (AM) is ever-evolving. While additive technology is a proven game changer, gaining a client's trust requires speed, agility, and simplicity, particularly in production and supply chain processes.

Joining Host Fabian Alefeld is Derek VanDenDriessche, Vice President of Sales and Business Development at Precision ADM. Precision ADM is a contract manufacturer specializing in AM. Derek has extensive experience in building successful AM production chains. He explains Precision’s three-step process from prototype to production, the value of partnering with a contract manufacturer, and the challenges of producing parts for the medical and aerospace industries.

All opinions expressed by podcast participant(s) are so current opinions and do not reflect the opinions of EOS GmbH or the podcast participant(s) respective companies and/or affiliates. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[3:31] Who is Precision ADM and how do they maintain supply chain agility? 

[8:36] Derek details Precision ADM’s 3-step process from prototyping to production.

[11:29] Derek explains the similarities and challenges of handling additive production for the aerospace and medical industries.

[13:31] What criteria demonstrate the value of partnering with a contract manufacturer versus vertically integrating additive production?

[18:26] How is Precision ADM pushing the additive manufacturing industry forward?

As additive manufacturing (AM) practices and processes mature, we are reminded daily of the boundless potential and transformative power of technology, especially in the healthcare industry. However, additive manufacturing can be a confusing arena for traditional medical manufacturers to step into. Large organizations that successfully integrate additive are essential components of the technology’s wider adoption.

Joining Host Fabian Alefeld is Mark Morrison, Senior Research Manager at Smith & Nephew. Mark has decades of experience in both additive manufacturing and material science. Their conversation explores the significance of material science in AM, Mark’s unique journey, and sheds light on Smith & Nephew’s achievements including producing hundreds of thousands of patient-specific applications. Mark highlights key applications driving AM adoption and the importance of porous structures in the medical space. They also address the patient-specific perspective, the challenges of integrating AM into big business, and how the industry is navigating the experience gap between traditional methods and modern industrial 3D printing.

All opinions expressed by podcast participant(s) are so current opinions and do not reflect the opinions of EOS GmbH or the podcast participant(s) respective companies and/or affiliates. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:55] Mark’s appreciation for understanding why things behave the way they do triggered his journey into material science and additive manufacturing.

[5:03] In the medical industry, what current applications can be enhanced by additive manufacturing, and what are the patient benefits?

[10:33] What challenges or limitations does Mark foresee for integrating additive manufacturing more broadly in the medical space?

[15:46] What role does the FDA play in assisting organizations to qualify additively manufactured implants to make them market-ready? 

[19:31] What excites Mark when he thinks about current and future additive applications?

With the top five orthopedic organizations using metal and polymer additive manufacturing for production parts, the space industry using it daily for critical applications, and the automotive industry ramping up, it means this is just the beginning of a very exciting additive manufacturing (AM) journey.

Joining Host Fabian Alefeld is Chuck Hansford, Director of Advanced Development at Tecomet. In the US, Chuck is widely known to be one of the most experienced metal additive manufacturing experts in the medical industry. He provides profound insights on where AM is currently as a technology and where it will be in the future, what makes clients adopt AM, and guidance for the next generation of AM innovators.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[:45] Chuck describes his early days of testing the boundaries of additive manufacturing in plastics, then metals.

[5:37] Chuck explains where the medical industry stands when it comes to adopting additive manufacturing.

[9:41] Chuck gets technical about the product development lifecycle, adoption of AM in the medical industry, and resolving trapped powder particles.

[23:00] What are AM adoption rates and trends in the medical space?

[28:27] Chuck’s key guidance for engineers, C-levels, and operators who may be skeptical about adopting additive manufacturing.

The impact of additive manufacturing (AM) is expanding within the medical industry. With customization and quick turnaround times for products essential for exceptional patient care, the vertical integration of additive and traditional manufacturing is making this requirement a reality. This paradigm can function as a role model that can be applied to other technologies and industries, further solidifying the benefits of its adoption.

Joining Host Fabian Alefeld is restor3D's brilliant co-founder and CTO Cambre Kelly. Cambre is a key figure behind the company's impressive success and recently joined the Forbes 30 under 30 list in the manufacturing and industry sector. In addition to sharing restor3D’s unique and innovative business model, Cambre explains how restor3D views the intersection of additive manufacturing, personalized healthcare, and artificial intelligence.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:16] Cambre describes her education, research, and career journey that led to her specializing in 3D-printed porous structures in orthopedics.

[3:35] Cambre delved into unexplored territory researching optimized gyroid lattice structures for orthopedics.

[6:52] Founded in 2017, restor3D has been successful in the complex task of vertically integrating additive and traditional manufacturing without outsourcing.

[16:08] In an effort to bring more personalized solutions to the orthopedic market, restor3D recently acquired companies that will expand their reach.

[20:33] Restor3D endeavors to be technology agnostic and utilize AI tools for design efficiencies. 

Additive manufacturing (AM) has transformed medical devices such as hearing aids, dental procedures, and implants. There is further opportunity to expand and innovate the space, but are the regulatory bodies and insurance companies ready to adopt the technologies? 

Host Fabian Alefeld is joined by the founder and principal consultant of LG Strategies, Laura Gilmour. Laura has extensive experience in additive manufacturing and in particular in the medical market. Laura offers a comprehensive overview of the medical industry as a whole and discusses the challenges of its adoption of additive manufacturing and the current medical industry trends where additive manufacturing is making a big impact. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key takeaways:

[:54] Laura shares her unique AM journey within the medical markets industry.

[3:12] Laura describes the medical sectors AM is helping to revolutionize including hearing aids, hip implants, and digital dental applications for the medical implant industry.

[11:15] When implementing AM in the medical space regulatory reviews and insurers can be the biggest hurdles.

[16:04] The risk versus benefits requirements of the primary regulatory bodies.

[21:21] How IQ, OQ, and PQ processes apply to the medical device industry. 

[24:41] Laura highlights trends in the medical industry with regard to the benefits of additive manufacturing innovations. 

Additive manufacturing (AM) has forged a foothold in countless manufacturing applications due to its versatility and design freedom, but it is not always the all-in, right fit, right now for some industries. One example being manufacturing millions of end-use products for the consumer goods industry. Still, AM’s digital supply chain advantages have secured its place in the consumer goods value chain.

Today, joining Host Fabian Alefeld is Ronen Hadar, the Senior Director of Additive Design and Manufacturing at The LEGO Group. Ronen has a unique perspective on the advantages and challenges of working with AM in the consumer goods industry. He shares the long history of AM within the LEGO Group, how the famous ‘duck’ project came about, and how a limited talent pool may affect new digital technologies.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[:46] In 2010, Ronen began exploring how AM could alleviate supply chain challenges at the LEGO Group.

[3:29] From prototyping to on-demand final designs, Ronen explains how the LEGO Group was one of the initial companies to adopt 3D printing for multiple applications.

[10:59] Ronen explains why he asserts that AM is not a replacement for injection molding.

[12:52] While scouting new technologies, the LEGO Group’s now famous duck was an application to highlight the advantages of AM.

[21:05] For the consumer goods industry, Ronen shares what he sees as the biggest challenges for the adoption of AM as an end-user technology.

[28:25] How does the LEGO Group handle the small talent pool available to work in AM applications?

Additive manufacturing (AM) has the potential to reshape industries and enhance lives – complete from head to toe. Podiatry is an area where inspiration and innovation help customize an end-user product by blending AI, a platform-based business model, and additive manufacturing technology to create a medical application that enhances people’s lives. 

Today, Host Fabian Alefeld is joined by Travis and Nathan Eadie who called in from the Australian Podiatry Conference. Travis and Nathan are an innovative brother duo behind the company Doc Sols, a revolutionary company making strides in podiatry with their additively manufactured orthopedic insoles. This episode promises a riveting discussion about their journey, their challenges and triumphs, and their vision for the future of AM in healthcare.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:09] How Nathan, a sports podiatrist, and his brother Travis, a tradesman began creating custom insoles 25 years ago.

[6:51] Nathan and Travis describe the full-process chain, from the app to the 3-D printed end product.

[10:36] How does additive manufacturing mixed with AI benefit customers of insoles who have different orthopedic needs?

[18:06] What major challenges have Nathan and Travis experienced that stifled their progress of using AI with additive manufacturing?

[24:42] What does the Doc Sols platform-based business model look like five years out?

Additive manufacturing’s (AM) role in the groundbreaking area of enhancing athlete safety through new design freedoms or on-the-spot custom polymer pad printing is nothing short of remarkable. Whether it's a helmet, a knee pad, or even the shoes on a player's feet, the sports equipment of tomorrow is being revolutionized today with AM.

To unravel the intricacies of this fascinating subject, Host Fabian Alefeld is joined by the Professor & Director School of Kinesiology & Nutrition at the University of Southern Mississippi, Dr. Scott Piland. Scott is an expert at the intersection of sports and technology. He has been on the front lines of research and development, discovering how AM is sculpting the future of player safety devices and other crucial equipment.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:02] Scott explains his journey from shoe salesperson to athletic trainer to a respected sports safety and AM material integrator.

[7:24] Scott shares his thoughts on the future role of AM in kinesiology and sports sciences. 

[14:13] The benefits AM offers to sports equipment designers to transform sport safety devices.

[21:27] How multidisciplinary groups use AM as a vehicle to innovate and transform a wide range of industries.

[26:51] Scott shares real-life applications of AM in sports and the long-term user benefits of technological enhancements.

Additive manufacturing (AM) popularity is growing rapidly within the consumer product and sporting goods application space. This series examines the AM innovations that are transforming industries, in this case, sporting goods. Safety, stamina, and grit are all enhanced by precise equipment designs that provide a perfect fit for professional and recreational athletes. AM is the only technology that can deliver custom designs at the fast pace that sporting goods suppliers require. 

In this episode, Host Fabian Alefeld is joined by Engineering Manager for Advanced Product Development at Bauer Hockey, Thierry Krick. Thierry and the team at Bauer use EOS technology to design and produce protective equipment and customized products for hockey players. Conn Smythe Trophy winner, Cale Makar recently won MVP while wearing a custom Bauer hockey helmet, made in part with industrial 3D printing. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[3:08] Why is AM suitable for designing high-tech sports equipment?

[4:01] Thierry explains how a small piece of foam sparked a complete manufacturing revolution at Bauer Hockey.

[10:45] Why Thierry chose powder technology to be the production path for the future at Bauer.

[15:43] From R&D to production, Thierry shares the many different assets involved in creating a viable sports helmet.

[20:29] Thierry reveals the hockey helmet and explains how each helmet is fitted to an athlete's head. 

[25:24] How athletes can get their own Perfect Fit Helmet from Bauer. 

Additive manufacturing (AM) is not only a tool to enhance the performance of applications and create more agile supply chains – it’s also becoming a tool to increase brand value and awareness. Today, we dive into the story of the innovative engineering and viral marketing of the first ever 3D printed, Airless Prototype Basketball developed by Wilson Sporting Goods.

Host Fabian Alefeld is joined by Dr. Nadine Lippa, Innovation Manager at Wilson Sporting Goods, and Tyler Webb, Sports Marketer and Co-founder of Uncle Charlie. Nadine, the brilliant mind who led the product development of Wilson’s Airless Prototype Basketball, shares behind-the-scenes moments from the project’s origin to meeting Shaquille O’Neal and Mark Cuban courtside. Tyler, the creator of the viral video that sent ripples across the internet, shares how he made the Airless Prototype Basketball the most-seen additive manufacturing application ever created.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:27] Nadine describes what it felt like to be courtside at the NBA Dunk Contest when her 3D printed Airless Prototype Basketball was revealed.

[6:31] Wilson’s additive manufacturing journey didn’t begin with a basketball; Nadine shares some history.

[9:38] Nadine explains the complex process her team used to turn a polymer into a high-performance basketball and the biggest challenges the team faced.

[16:20] How did Wilson’s marketing efforts go viral to ignite a trend of combining additive manufacturing and sports?

[26:24] Tyler shares his thoughts about when he first saw Wilson’s Airless Prototype Basketball and what he sees as the future impact of additive in sports.

[35:49] Tyler explains how 3D printed products like the airless basketball can improve safety and performance in sports.

A majority of space applications and space companies would not be where they are today without additive manufacturing. In this final episode of our four-part series, we explore how additive technologies, like the ones used on the Ingenuity helicopter, can be used to advance industries and applications, such as mobility here on Earth.

Host Fabian Alefeld is joined by Professor of Engineering Design and Manufacturing at Penn State and additive rockstar, Tim Simpson. Tim runs one of the best additive manufacturing programs in the US. Students of his program can graduate with a master of engineering in Additive Manufacturing and Design. 

He also consults with the NASA Langley Research Center on system design and additive manufacturing. Today, Fabian and Tim discuss the
implications of the latest developments in the space industry and other industries.

We recommend you start with episode 1 of this 4-part miniseries to get a better understanding of the current state of AM in the space industry. Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[3:20] Equally interested in the design and manufacturing of mechanical and industrial applications, metal 3-D printing was Tim’s innovation trigger.

[5:36] Tim’s Penn State multidisciplinary engineering and design course connects research to real-world applications.

[10:29] At NASA, Tim examines how the advancements of AM in the space industry merge with other industries and technologies.

[21:10] Tim considers the current and future impacts of different technologies, such as OpenAI, on AM.

[27:44] Tim and a Ph.D. student coined the term MFD, or manufacturing fixation and design, to describe the limitations brought about by previous engineering experience.

The space industry could be the next trillion-dollar industry due to the vast technological advancements of the last decade. In this third episode of our four-part series, we discuss how even though AM lends itself perfectly to space applications, the rapid advancements in materials post-processing and the capabilities of engineers working on them will continuously accelerate the development of more efficient engines, reusable components, and completely new designs.

Host Fabian Alefeld is joined by Zach Cordero, MIT professor where he leads the MIT aerospace materials and structures laboratory and started a class for aeronautic engineers on additive manufacturing. Zach’s research spans from investigating new materials, specifically designed for additive to post-processing technologies that have the true potential to change material properties that are required for the most demanding applications in space, as well as aviation. 

We recommend you start with episode 1 of this 4-part miniseries to get a better understanding of the current state of AM in the space industry.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[2:09] Zach created his one-week crash course at MIT, to fill the need for workforce development of highly trained engineers.

[4:32] Zach explains the three main impact factors that make am perfect for the space industry.

[10:04] There are opportunities to develop new materials, but only two that offer economic gain to the developer. 

[13:16] Why Zach believes the space industry will benefit when additional design engineers enter the AM space.

[20:28] The future of post-processing in aerospace.  

In this second episode of our four-part series about space, we talk about the orbital stage of space exploration in detail. Host Fabian Alefeld, with the help of Launcher's Head of Manufacturing and Supply Chain, Tim Berry, examines the intricacies of the technology that's being used to develop orbit vehicles and equipment in the new space industry. Including to a significant extent, additive manufacturing. Tim is an engineer at heart, working for California-based rockets and spacecraft company Launcher.

We recommend you start with episode 1 of this 4-part miniseries to get a better understanding of the current state of AM in the space industry.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[2:24] Having the space bug from a young age, Tim shares his professional and personal journey into a lifelong career in the space industry.

[8:06] Tim explains why he accepted the position of Head of Manufacturing and Supply Chain at Launcher.

[11:10] The technology and applications driving Launcher’s Light and Orbiter models.

[15:00] A large portion of Launcher’s rockets are designed and made using additive manufacturing technology.

[20:38] Tim takes a deep dive into Orbiter’s three core missions and possibilities for the future.

[30:52] Tim looks into the crystal ball and shares what he sees in the future for additive, Launcher, and space industry.

There are thousands of private organizations with an interest in the space industry, prompting a new space race. This has been fueled in no small part by amazing technological developments in and outside the industry. In this four-part miniseries of Additive Snack, we explore the new space race industry, how it got to where it is now, and the role of additive manufacturing in our current environment and the future. In his first episode on space, Fabian Alefeld is joined by Paul Gradl, principal engineer at NASA and one of the most trusted sources of additive manufacturing knowledge in the space industry and beyond.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[3:33] Paul explains why he chose a career in the space industry.

[7:02] What was the first time AM and space collided and started their joint journey?

[13:02] Paul shares some current applications that NASA uses additive manufacturing to enhance.

[17:04] Paul describes how NASA works with private companies to accelerate the development curve and the speed of new space innovation.

[22:47] NASA has taken on the educator role by publishing an AM book and sharing their additive data.

 [27:21] Paul shares examples of failed additive parts that offered important lessons for process improvement.

[32:33] What will accelerate the adoption of additive, and what does the future of AM in space look like?

[38:37] What would the space race landscape be today without additive manufacturing?

Join host Fabian Alefeld for the lift off of Additive Snack Season 5: The AM Space Race. Listen in as Fabian and industry expert guests shine a light on the incredible advances additive manufacturing has made on our exploration of outer space. Follow Additive Snack now to be among the first to listen to the new and truly out-of-this-world podcast mini-series, the AM Space Race. 

Companies can struggle with taking on a challenging AM project without a solid education or a complete understanding of the technology. Focusing on understanding the technology with all its opportunities and its limitations can help companies identify applications where AM can add value for a positive business case. Starting simple to get some early wins is the key to unlocking all of the possibilities of AM. In this interview from the IMTS+ Creators Lounge, Additive Snack host Fabian Alefeld interviews Duann Scott the founder of Bits to Atoms and creator of the DfAM substack. They discuss new materials, new design tools, new business models, and the impact AM can have on the world.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[2:06] Duann shares his intentions of educating people about the design aspect of additive manufacturing.

[4:40] Duann created the DfAM substack as a way to get information out there with no gatekeepers, no filters, and no corporate narrative.

[7:16] Duann’s advice for individuals and companies when beginning the design process for 3D printing. 

[9:20] The MITxPRO AMx course is critical for educating designers and accelerating the growth of the AM industry.

[13:04] Duann shares thoughts on how to get the current and future manufacturing workforce interested and educated about additive manufacturing. 

[22:15] The efficient use of energy is one of the biggest impacts AM can have to create a better future. 

Shareables:

“Do something easy. Get an easy win to understand what is possible.”— Duann Scott of Bits to Atoms on how to start a design for 3D printing

“It’s not a magic box. It can do a lot but you need to put in a lot of work to make it happen.”— Duann Scott, Founder, Bits to Atoms

“Manufacturing can be a cool job. You get to make things which are substantial and change people's lives significantly.” — Duann Scott, Founder, Bits to Atoms  

“The risk of a project failure, if you overdo it, can actually overshadow the whole additive manufacturing journey.”— Fabian Alefeld, Host of the Additive Snack podcast

The potential for growth in Additive Manufacturing (AM) is vast, and it is an exciting time to be a part of the community. Whether you are new to the industry or a seasoned professional, trade shows can be interesting but for in-depth knowledge introductory training is key. In this interview from the International Manufacturing Technology Show (IMTS), Additive Snack host Fabian Alefeld interviews Mike Vasquez, founder of 3Degrees Consulting and the Advanced Manufacturing Experience (AMX). They discuss the AM community, education, and the ongoing advancements in metal and polymer materials in the industry. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[2:04] Mike describes the AMX education event and the opportunities it offers to the Additive Manufacturing industry at large.

[9:34] Mike highlights the impressive technology on display at IMTS.

[11:40] The 3Degrees Discussions podcast is inspired by the personal stories of those who work in AM.

[14:44] As a Materials Scientist and Engineer, Mike believes the material game has changed in a big way, especially in composites.

[16:10] Tips and tricks for understanding Additive Manufacturing standards, materials, and processes.

[19:49] Many AM companies have moved beyond prototyping to specialize in specific industries, such as space and tooling.

[24:03] Mike’s tips for those interested in entering the AM industry.

Shareables:

“It's opening the door a little, but to show people what the art of the possible is.”— Mike Vasquez, Founder, 3Degrees Consulting

“We are trying to be a bit more open-minded when it comes to new materials.”— Mike Vasquez, Founder, 3Degrees Consulting

“New materials continue to unlock new opportunities.”— Fabian Alefeld, Host, the Additive Snack podcast

There are many opportunities to leverage additive manufacturing (AM), whether it is localizing manufacturing, improving supply chains, or developing innovative parts by leveraging the design benefits of the technology. In this special live interview from the International Manufacturing Technology Show, Additive Snack host Fabian Alefeld interviews John Wilczynski, Executive Director of America Makes. America Makes is the research-centric national institute charged with driving the adoption of the additive manufacturing industry.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[3:06] America Makes is a membership-driven organization with strategic initiatives to broadly increase the adoption of additive manufacturing.

[6:54] What approaches can those in additive manufacturing take to further the initiative within the traditional manufacturing industry?

[12:49] As AM tech matures, John points out that the challenge is distributing the benefits and opportunities to traditional manufacturers.

[16:42] Even though additive manufacturing is a proven solution for localized manufacturing, calculating the demand signal continues to be challenging.  

[20:27] John describes the final hurdles AM will face before becoming an integral part of the supply chain and how business owners can justify the initial investment.

Shareables:

“Very few manufacturing processes are stand-alone.”— John Wilczynski, Executive Director, America Makes

“There is just not a supply chain that exists in an ecosystem we are able to take advantage of.”— John Wilczynski, Executive Director, America Makes

“Additive is proven to be a solution that works.”— John Wilczynski, Executive Director, America Makes

Integrating additive manufacturing (AM) offers manufacturers a unique opportunity to re-design product development without the restraints of the traditional manufacturing process. In this special episode of Additive Snack, host Fabian Alefeld speaks with returning podcast guest Rich Stump at the IMTS+ Creators Lounge in Chicago. The co-founder and CCO of Fathom describes several of the hybridized projects his organization is working on and his predictions about what to expect from the additive manufacturing industry as a whole and his newly publicly traded company are insightful and inspiring.  

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[:57] Rich describes his career history in advanced manufacturing and shares the exciting work his new company, Fathom is involved in.

[2:13] How Fathom evolved into the company it is today and what makes its hybridized model unique in the AM market.

[5:53] Leveraging 12 different multiple manufacturing technologies, Rich’s team produced 20,000 parts in 27 days. 

[10:11] Rick encourages his clients to incorporate AM into their manufacturing strategy and not as a competitor to existing processes.

[12:19] Change management is key when integrating additive manufacturing into traditional product development models, Rich explains. 

[14:10] What’s next for Fathom now that it’s public on the NYSE?

Shareables:

“We leverage multiple additive technologies alongside traditional manufacturing to change the way clients are developing and designing their products.”— Rich Stump, Co-founder and CCO, Fathom Digital Manufacturing

“The strength of additive manufacturing is to provide unique products.”— Fabian Alefeld, Host, Additive Snack podcast

“Additive manufacturing is a great enabling tool.”— Rich Stump, Co-founder and CCO, Fathom Digital Manufacturing

“The biggest barriers of growth for additive production parts are awareness, education, and the economic envelope.” — Rich Stump, Co-founder and CCO, Fathom Digital Manufacturing

Additive Manufacturing (AM) is an integral part of pre-existing value and supply chains in the manufacturing industry. AM doesn't replace conventional manufacturing, it enhances it. In this special episode of Additive Snack, host Fabian Alefeld is joined by a panel of influencers and experts in manufacturing at the IMTS+ Creators Lounge in Chicago. IMTS is all about innovation and innovation is all about challenging the status quo. Mitch Free, James Soto, Meaghan Ziemba, Charli Matthew, and Scott MacKenzie share what the future of manufacturing looks like and the role manufacturing will play to create a better future for us and future generations. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:52] Scott MacKenzie of Industrial Talk highlights the power of human collaboration in manufacturing.

[4:08] Meaghan Ziemba’s Mavens of Manufacturing platform provides a microphone for women in manufacturing to inspire younger generations.  

[7:25] Mitch Free of ZYCI describes how integrating AI and automation will mitigate the skill shortage and lessen the learning curve. 

[9:50] Charli Matthew’s Empowering Industry and the Empowering Women podcasts showcase the human elements and digital technology shifts in the pump and related equipment industry.

[14:14] James Soto contends that to build a better future in manufacturing, it needs to reflect who we are.  

[19:11] James explains IMTS + and the IMTS Creators Lounge. 

Shareables:

“You have to collaborate with somebody that you trust.” — Scott MacKenzie, Host, Industrial Talk podcast 

“There will be an estimated gap of 2 million open manufacturing jobs by 2030.”— Fabian Alefeld, Host, Additive Snack podcast

“Women are a great asset for manufacturing because we know how to tell the stories, we know how to bring out the human aspect, and make the emotional connection to the younger generation.”— Meaghan Ziemba, Mavens of Manufacturing

“We have great challenges around skill shortages … I think AI will play a huge part in solving the learning curve.” — Mitch Free, Owner & CEO, ZYCI  

“The future of manufacturing, for me, has more women in leadership roles.” — Charli Matthews, Host, Empowering Industry podcast  

“Manufacturing needs to reflect who we are, what we look like, who we love.” — James Soto, Founder & CEO, Industrial Strength Marketing

Have you ever heard of fusion energy? Maybe you have some discussions about futuristic technologies but what if I told you the future is now? What if I told you that additive manufacturing (AM) already plays a significant role in it? Don't believe me? TAE is developing a commercial fusion power source that is compact, cost-effective, capable of sustaining the planet for centuries, and safe in every way. 

In this third and final episode of The Future of Energy mini-series, host Fabian Alefeld speaks with the Chief Marketing Officer at TAE Technologies, Jim McNeil, and Vincent Pilard, TAE’s Senior Mechanical and Project Engineer about their advanced approach to meeting the global energy demand. They discuss how TAE is leveraging all of the benefits of additive manufacturing including the capabilities of design freedom, optimizing existing designs, challenging geometries that allow for a better heat transfer, lightweighting, supply chain optimization, and the reduction of material for sustainability reasons.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:30] For over 24 years, TAE’s mission has been to create clean, carbon-free, radioactive-free, abundant baseload energy through fusion. 

[3:16] Jim explains the difference between nuclear fusion and nuclear fission and how to TAE plans to create the perfect power source. 

[7:48] Vincent explains the complex process of how fusion creates energy and the fascinating machine TAE will use to harness it.

[15:56] Is fusion technology competitive with other energy technologies such as conventional and renewable?

[16:51] Vincent shares the opportunities made available by working with Additive Minds and the benefits of additive manufacturing for TAE.

[23:10] To meet the global demand for energy, TAE is already preparing for the future using fusion and additive manufacturing as critical parts of the strategy. 

Shareables:

“The perfect example of how AM is such an innovative technology is not even comparable to the impact of the technologies it enables.” — Fabian Alefeld, Host, Additive Snack podcast

“Fusion is nature's preferred energy source.”— Jim McNeil, Chief Marketing Officer at TAE Technologies

“It is amazing to see how Am enables fast proto-typing and design iterations. It is a new approach to design. It gives a lot of agility to engineering to validate concepts.”— Vincent Pilard, Senior Mechanical and Project Engineer, TAE

“When we can provide abundant clean power for all nations, where they don’t have to go to war for resources, and that can change everything.” — Jim McNeil, Chief Marketing Officer at TAE Technologies

In the first episode of the Additive Snack mini-series, The Future of Energy, we discussed how gas turbines and hydrogen from electrolysis will play a crucial role in transitioning into a future of clean energy. But, these solutions can not be relied on to pull all the weight. Renewable energies and smart carbon-capture technologies also need to be part of the solution. 

In this second episode, host Fabian Alefeld speaks with Jeremy Haight, Principal Engineer and Lead Specialist for additive manufacturing (AM) and Advanced Concepts at Vestas, and Stefan McClelland, Senior Mechanical Engineer at ReCarbon. They take a deeper look into wind turbines and carbon capture and utilization from landfills. Both technologies leverage Additive Manufacturing at different levels and will have a significant impact on how the world produces and consumes energy. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:55] Jeremy describes Vestas’ lengthy history from manufacturing household appliances to becoming a global leader in wind turbines.

[4:44] Vestas has a three-pillar approach to incorporating AM parts, embracing new technologies, and digitizing their manufacturing processes. 

[12:22] Utilizing AM technologies for on-site mobilized manufacturing will be a game changer for Vestas.

[14:32] Jeremy gets specific about how Vestas leverages a broad spectrum of AM technologies.

[18:42] The long-term impact of AM on the world's transition to renewable energy.  

[21:37] At Vestas new products are designed with AM in mind to prolong life cycles and decrease shipping costs.

[24:17] Jeremy cites several examples of the beneficial effects of AM on wind turbines.  

[29:57] Stefan describes the unique process of how ReCarbon converts energy into syngas through plasma. 

[34:38] AM is essential in ReCarbon’s design due to the thermal management required for the high temperatures inherent in their energy creation process.  

[40:12] AM has streamlined the proof of concept process for ReCarbon and its clients. 

[44:38] Fabian summarizes the incredible conversations about how AM impacts the future of energy through carbon capture and wind energy. 

Shareables:

“The more complex technologies get, the more additive manufacturing can play a role in supporting the development of the technologies.” — Fabian Alefeld, Host, Additive Snack podcast

“It [AM] will reduce our time to market, get turbines out in the field and up and operational much faster.”— Jeremy Haight, Principal Engineer & Lead Specialist for AM & Advanced Concepts, Vestas

“There is a huge potential for us to lightweight the product so you get more lifecycle out of it.”— Jeremy Haight, Principal Engineer & Lead Specialist for AM & Advanced Concepts, Vestas

“We've been restricted to using additive because with the material choice we need to have we need something that can handle the temperatures and handle really fine geometries.” — Stefan McClelland, Senior Mechanical Engineer, ReCarbon.

Global warming is dramatically altering the world around us. And, as the population of the world continues to increase so does the demand and consumption of global energy. The fascinating world of energy and how additive manufacturing (AM) will impact it in the future is inspiring. Let's jump into jointly investigating how these technologies work, what attributes they bring to provide energy for current and future generations, and the contributions of AM to help us transition to a carbon-free future by 2050. 

During today's episode, Fabian speaks with Quan Lac, VP of additive manufacturing at Siemens Energy, and Pierre Forêt, Head of AM at Linde about how AM is impacting the transition toward clean energy. Quan shares how Siemens Energy is utilizing AM-created pieces to further enhance gas turbines, supplement other necessary energy equipment, and how they are preparing to transition to green fuels. Pierre describes how Linde uses AM to release the full potential of hydrogen to increase volume and reduce the cost of green hydrogen. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[0:44] Fabian describes the climate drivers ushering Additive Manufacturing deeper into the energy sector.

[2:55] Fabian introduces the expert guests who participate in this conversation. 

[3:54] The history of natural gas as a fuel source for humans.

[6:00] Quan Lac VP of AM at Siemens Energy explains how the company plans to energize society into an energy sustainable future and how AM fits into the mission. 

[13:21] Quan describes how Siemens plans to support decarbonization. 

[16:23] How gas turbines work and how AM contributes to the restoration of existing units and the development of new more efficient units.

[25:50] Quan explains Siemens plans for the future including modifying gas turbines to include hydrogen.

[30:52] Pierre Forêt, Head of AM at Linde Gas, describes how Linde produces and distributes industrial gas products and his role at the company.

[33:18] Pierre defines green hydrogen and sheds light on the exciting opportunities it affords.

[38:51] How Additive Manufacturing can drive down the cost of green hydrogen and increase the performance of existing processes.

[43:05] Future opportunities for green hydrogen to assist industries to impact decarbonization.

[46:16] Pierre describes the barriers and challenges to releasing the full potential of hydrogen. 

Shareables:

“How do we transition humanity into carbon-free energy?” — Fabian Alefeld, Host, Additive Snack Podcast

“There are nearly 800 million people today who don’t have access to electricity.”— Quan Lac, VP of Additive Manufacturing at Siemens Energy

“Is there a better moment than now to choose AM to produce better smarter components?” — Pierre Forêt, Head of AM, Linde Gas

You no longer have to be a billion-dollar behemoth to enter and impact the additive manufacturing (AM) field. There is a need for new thinking, new ideas, and new approaches for solving both industrial and major global issues, and startups are shaping the industry far more than they get credit for. In this episode, Host Fabian Alefeld speaks with Arno Held, Managing Partner of AM Ventures about the startups his team is funding and how their innovative impacts are shaping the future of AM. 

During today's episode, Fabian talks to Arno about some exciting trends and industry insights AM Ventures has identified in recent years, the necessary innovations in technology, materials, applications, and software essentials for success. Arno busts a few AM myths and offers a glimpse into his thoughts about post-processing and post-build automation opportunities. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[3:01] After speaking with hundreds of startups, Arno shares exciting trends popping up in the AM space.

[10:35] Innovative designs offer opportunities for alternative materials in AM applications.

[15:29] Design software is finally catching up to the potential of AM technology.

[18:59] With new complexities come new responsibilities but the possibilities of AM are endless. 

[20:03] Technologies that may positively impact the advancement of AM technology. 

[23:57] Experienced and hopeful are the two most common types of pitches AM Ventures is approached with and Arlo’s advice for startups.  

Shareables:

“A big part of AM Ventures’ mission is we want to support industrial additive manufacturing startups all around the world.” — Arno Held, Managing Partner, AM Ventures

“My advice for startups — Find a real problem and companies who are willing to pay money for it to be solved.”— Arno Held, Managing Partner, AM Ventures

“We have software out there that is utilizing the freedom of design our technology enables.” — Arno Held, Managing Partner, AM Ventures

In this episode, Host Fabian Alefeld speaks with Lin Kayser, CEO of Hyperganic Group. Lin shares the knowledge and vision he acquired from being a successful tech entrepreneur for more than 30 years. Lin has gone from industrial automation to bringing the Hollywood film industry into the digital age. He has had leadership roles in organizations focused on sustainability, renewable energy, and space flight. His company, Hyperganic, wants to radically change the way objects are engineered and designed using advanced algorithms to help engineers achieve groundbreaking design complexity. 

During today's episode, Fabian talks to Lin about what inspired him to start Hyperganic Group, how Hyperganic’s innovative platform can change the way products are engineered and designed, why the platform is the perfect fit for the next generation of Additive Manufacturing (AM) and AM engineers, and his vision for the future of AM and code-based design. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:54] Lin’s dynamic career path progressed from accidentally inventing a movie playback software to buying a 3D printer and creating Hyperganic.

[7:03] Lin describes how Hyperganic changes the game in manufacturing. 

[12:38] Can current software engineers be supercharged to bridge the gap in manufacturing jobs and code-based design? 

[19:16] Hyperganic is creating highly-optimized objects on demand, appropriate technologies, and client-specific applications. 

[23:54] Lin’s vision for the future of AM includes licensed algorithms and humanless factories. 

Shareables:

“In 2008, when Al Gore gave his famous talk on an Inconvenient Truth on climate change. And that kind of shook me awake. I joke that I thought we had already solved the environmental crisis by separating our trash. And here is this guy talking about this monster that is barreling down on us. I felt what the hell am I doing in the entertainment industry.” — Lin Kayser, CEO, Hyperganic 

“Hyperganic tries to dramatically accelerate innovation by moving manufacturing and engineering to a software paradigm.”— Lin Kayser, CEO, Hyperganic

“There is one aspect of our technology that is interesting. What you do when you create an object using our technology is you don't create an object, you create a process that creates objects.” — Lin Kayser, CEO, Hyperganic

In this episode, Host Fabian Alefeld speaks with Brian Neff. Brian is the CEO of Sintavia and Chairman of the Board of Additive Manufacturer Green Trade Association (AMGTA). Sintavia is an aerospace manufacturer that uses 3D printing technology to achieve the next levels of engine performance, thermodynamic efficiency, part consolidation, and sustainability for its customers.

From the Austin studio, Brian shares what makes additive manufacturing (AM) a perfect fit for building rocket engines, Sintavia's unique role at the crossroads of aerospace innovation and additive expertise, and how Sintavia is helping the aerospace industry overcome resistance to change. In addition, he describes how AM achieves new levels of sustainability for manufacturers and their customers, how Sintavia is using AM to enable next-generation aerospace innovations from fully electric aircraft to space travel, and the emerging AM capabilities and materials he is excited about.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:53] Brian explains that multi-generational modality changes in aerospace are what excites him.

[4:30] How Sintavia differentiates themselves and their impact on the aerospace industry.

[8:17] What Brian considers barriers to AM adoption and how Sintavia overcomes the barriers.

[10:13] How AM is helping to enable sustainable manufacturing technologies and how Sintavia is approaching new applications. 

[22:12] The AM incentives that will transform the traditionally conservative aerospace industry. 

[26:09] How the ever-evolving AM industry’s emerging capabilities will impact the aerospace industry and what changes Brian envisions for the future of space travel. 

Shareables:

“I was first introduced to AM in 2011 when I was running a jet engine repair company and toured a competitor in Bavaria.” — Brian Neff, CEO, Sintavia

“Sintavia is a combination of a company that understands aerospace quality, understands additive technology, and brings them together in two very important and critical product categories which are the next generation of flight and launch engines and the next generation of heat exchangers to cool them.”— Brian Neff, CEO, Sintavia

“In 2019, we came up with the AMGTA. The whole purpose of the AMGTA is to take a very hard, very accurate look at how the technology [AM] is more sustainable, and create pathways and strategies for companies, using specific raw additive technologies, to use those properly.” — Brian Neff, CEO, Sintavia

“100% of all private commercial rocket engines, at least the thrust chambers for those, are printed. 100% across the industry of the eight companies that have either launched into space or are about to launch into space every single one of those rockets is printed.”— Brian Neff, CEO, Sintavia

“Sustainability to me is the other side of operational efficiency.” — Brian Neff, CEO, Sintavia

Fortune favors the bold when it comes to additive manufacturing (AM). Many companies begin with a simple application of AM, which is fine, but to continuously unlock long-term success for AM, the real opportunities for innovation, performance, design improvements, and market differentiation you will need to be bold. NASCAR champion Brad Keselowski is a bold individual on the race track and within the company he founded, Keselowski Advanced Manufacturing. His organization is on a mission to lead the fourth industrial revolution. His team's state-of-the-art AM capabilities are a big part of that effort. 

In this episode, Host Fabian Alefeld speaks with Brad about how he was introduced to 3D printing, why NASCAR and AM have more in common than many think, how Keselowski Advanced Manufacturing has been able to grow so quickly, and Brad's advice for organizations who are at the beginning of their AM journey.

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[2:25] Plastic 3D printing wasn’t an option for the high-intensity needs of a race car, but in 2017 metal 3D printing helped facilitate Brad’s desire to win. 

[6:31] Common threads between additive manufacturing and motorsports.

[10:37] How Brad manages growth and challenges at Keselowski Advanced Manufacturing (KAM). 

[13:28] Process control and vertical integration are key components of KAM’s success, and when they do fail, they fail forward.

[18:08] How to overcome the biggest challenges in AM and the importance of finding the best use case. 

Shareables:

“I start everything I do with — what is it going to take to win? — and in a lot of ways technology is what we need to win.” — Brad Keselowski, NASCAR Champion, and Owner/Founder of Keselowski Advanced Manufacturing

“The factory we use in [AM] is a lot like a race car factory. A racecar factory is hyper-organized, very-process based, speed to market is very important, it is very clean, and all of those things are important in an AM landscape..”—Brad Keselowski, NASCAR Champion, and Owner/Founder of Keselowski Advanced Manufacturing

“Our biggest challenge at KAM, and I think this is very much the case in a lot of the AM industry, is the experience of program managers, buyers, engineers in the industry to date.”— Brad Keselowski, NASCAR Champion, and Owner/Founder of Keselowski Advanced Manufacturing

“If you just want to start with AM on a simple project, that’s okay, but it is probably not going to give you long-term success. Make sure you find the right use case.” — Brad Keselowski, NASCAR Champion, and Owner/Founder of Keselowski Advanced Manufacturing

Many people mistake failure as a shortcoming of additive manufacturing (AM). In many cases, it is more about the time and effort needed to learn entirely new processes. AM is an enabler of agility. It is helping organizations become more agile and solve problems more effectively. For the past few years, AM has helped companies work around supply chain challenges. By exploring AM as a stop-gap solution, you can overcome temporary disruption, but you can also discover long-term solutions to manufacture more effectively.

In this episode, Host Fabian Alefeld speaks with Rich Stump, co-founder, and CCO of Fathom, an on-demand digital manufacturing service provider that recently announced it is going public. Rich, and Fathom, have been at the forefront of the AM revolution for more than a decade. Rich describes how Fathom has evolved alongside AM's capabilities. We talk about how Fathom is helping its customers learn how to design for AM, how gateway applications can help new companies adopt AM, and where the AM industry and Fathom are headed in the future. Rich shares insights that only a true additive manufacturing leader could know.

The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:53] Rich describes his journey through different technologies to arrive at additive and advanced manufacturing and the life-cycle of Fathom.

[7:45] Rich explains how Fathom is unique in the AM arena.

[9:32] An impressive example of how Fathom met a unique customer need using 12 different manufacturing processes with a critically short timeline.

[12:29] The agility of AM allows companies to reduce their product development timelines.

[14:16] Fathom’s outcome-focused approach allows clients to see how AM can enhance their product development and manufacturing processes.

[17:51] Rich and Fabian discuss the future workforce of AM, gateway applications that can accelerate AM’s widespread integration and the role of AM in alleviating supply chain challenges.

[25:59] Rich’s guidance to those interested in incorporating AM into their manufacturing process — start with a simple application.

Shareables:

“I'm passionate about this industry and how we can think differently to use new technologies to solve interesting problems — to accelerate and innovate the product development process.” — Rich Stump, Co-founder, and CCO of Fathom on The Additive Snack Podcast

“It’s about using additive alongside traditional manufacturing, to solve the right problem for the right application. We are technology neutral.”— Rich Stump, Co-founder, and CCO of Fathom on The Additive Snack Podcast

“Today, more than ever, we have access to technologies at price points and ease of use that in the past were either very expensive or very hard to use, which brings a lot more agility to the whole product development process.”— Rich Stump, Co-founder, and CCO of Fathom on The Additive Snack Podcast

“Find an application that is an easy win and then build upon that. You have to build the culture of adoption, and in order to do that you have to change the mindset of the organization to adopt a new manufacturing process.” — Rich Stump, Co-founder, and CCO of Fathom on The Additive Snack Podcast

3D printing is now a core solution for many industrial applications. Companies that wait to explore Additive Manufacturing (AM) run the risk of falling behind competitors in their respective markets. Plus, the earlier organizations become familiar with AM, the more data and expertise they will gain. Expertise is very important when explaining the key value propositions of AM as well as the reliability to customers and users. As soon as an organization adopts AM as a fundamental tool the more design engineers and the general workforce will embrace the opportunity to solve problems with innovative technologies and materials. In this episode, Host Fabian Alefeld speaks with Matthew Parker, Director of AM Engineering at Senior Aerospace SSP about how to successfully navigate an AM journey. Senior is a company that designs and manufactures some of the most demanding and complex parts for the military space.

The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:31] Matthew describes his role at Senior, recounts when they decided to adopt AM as a production technology and shares the applications they launched first.

[8:39] How Matthew faces the challenge of client doubt and resistance toward AM and proves that Senior has the experience to help them through their AM journey.

[10:42] Scaling AM into an organization begins with educating engineers and keeping up with the ever-changing technology.

[13:32] Cost is not the only driver when it comes to companies embracing AM in production opportunities.

[17:51] Hesitant customers who lack confidence in AM technology may be left behind in the sustainable applications market and green technology opportunities.

[20:30] Matthew’s advice for companies on the fence about AM, start early and invest.

[23:37] With a solid business case, design engineers will get the ear of senior decision-makers when introducing AM.

[28:02] How to get people excited about AM and how to spread AM expertise throughout a workforce.

Shareables:

“Additive Manufacturing allowed us to design ducting that would squeeze through very tight sections of this aircraft which allowed us to provide our customer with a solution that would not have been possible otherwise.” — Matthew Parker, Director of AM Engineering, Senior Aerospace SSP on The Additive Snack Podcast

“Initially engineers like to think that everything can be additive. And, that is also a challenge — educating the engineering workforce on what are viable candidates for AM, what are better kept traditional, or what are better as hybrids.”— Matthew Parker, Director of AM Engineering, Senior Aerospace SSP on The Additive Snack Podcast

“If you don't invest ahead of the need, then you will not be ready when the customers come in asking.”— Matthew Parker, Director of AM Engineering, Senior Aerospace SSP on The Additive Snack Podcast

The first rule of 3D printed polymers is the need to rethink applications at the specification level. Part specifications and properties can be improved upon dramatically with additive manufacturing. If you remain focused on legacy materials, specs, and processes you may miss out on the best opportunities to innovate. Host Fabian Alefeld speaks with Dr. Cary Baur, Senior Manager Polymer Technology of EOS, about the best ways to approach innovation with 3D printed polymers, how to separate legacy thinking from an AM strategy, and future materials that meet application requirements and provide for new opportunities.

The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:43] A general overview of polymer materials suited for 3D printing and why nylons are ideal. 

[6:21] Consider the minimum requirements when choosing a new material and be open to change to leverage AM. 

[8:52] Cary describes the base polymers, fillers, and new materials being used in AM.

[14:23] An example of how Cary’s team designs and develops new materials to meet a client’s performance requirements.

[20:55] Engineering variables to consider to control consistency and reproducibility of an AM process and output. 

[27:27] New applications and new frontiers being pushed by additive manufacturing solutions.

[33:27] How and why to separate legacy thinking from a polymer AM strategy.

Shareables:

“The most effective way to target new applications in laser sintering is by having an openness and an understanding that your specification might have to change to accommodate a new material.” — Dr. Cary Baur, Sr. Manager, Polymer Technology, EOS on The Additive Snack Podcast

”Many customers enter additive manufacturing by actually converting existing parts first with the roadmap later of designing specifically for the process.— Dr. Cary Baur, Sr. Manager, Polymer Technology, EOS on The Additive Snack Podcast

“We are more and more being tasked with understanding the variables that we can control understand the variables that could we can monitor and understanding what we cannot control .”— Dr. Cary Baur, Sr. Manager, Polymer Technology, EOS on The Additive Snack Podcast

We are entering a golden era for 3D printable metal materials. This means manufacturers in many industries will be able to create things they never have before. Host Fabian Alefeld speaks with Dr. Ankit Saharan, Senior Manager of Metals Technology at EOS. Today’s discussion focuses on the past, the present, and the future of metal additive manufacturing (AM) materials. The future takes center stage because a new class of 3D printable superalloys, Metal Matrix Composites (MMC), high entropy alloy, and pure metals will enable incredible new applications for the space industry, semiconductor industry, electronics industry, and many other verticals. Ankit explains what MMCs or high entropy alloys are and what they mean in terms of exciting new applications.

The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:27] Ankit shares the history of additive manufacturing using metals and how it unlocked future potential.

[6:42] How AM evolved from a centering process into a serial production technology.

[9:31] When developing custom projects with new materials initial resistance will be a challenge.

[15:56] Metal Matrix Composite and High-entropy alloys: What they are, the benefits, and what they mean for the future of additive manufacturing.

[22:28] Choosing one material or a process over another comes down to performance over substitution.

[26:01] Artificial intelligence and new materials escalate the future of AM.

Shareables:

“Materials and processes go hand-in-hand. No matter how much you try to separate them, they always go hand in hand.”— Ankit Saharan, Senior Manager of Metal Technology, EOS, on The Additive Snack Podcast

“We've got much better tools at our disposal like machine learning, artificial intelligence that we've never had before. It enables us to not only iterate faster in terms of material composition but also be able to predict what they are going to give us before we even make these materials physically.”— Ankit Saharan, Senior Manager of Metal Technology, EOS, on the Additive Snack Podcast

“We are reaching a tipping point in additive manufacturing. AM can not be removed out of the supply chain anymore because it produces components that can not be produced with any conventional manufacturing technology anymore.” —Fabian Alefeld, EOS and Host of the Additive Snack Podcast

Host Fabian Alefeld speaks with Markus Seibold, Vice President of Additive Manufacturing at Siemens Energy and Material Solutions, two of the most advanced users of Additive Manufacturing (AM) consumer production. Markus and Fabian discuss why a working culture focused on growth and a shared sense of purpose is far more effective than a culture focused strictly on performance, best practices for creating and nurturing a growth mindset for teams, the bold moves Siemens Energy has made to successfully enable innovation through Additive Manufacturing, and why AM engineers and designers don't get enough credit.

The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:32] Markus has two diverse roles — driving AM into Siemens Energy’s core product base and expanding the Material Solutions business. 

[4:09] Siemens energy's approach to creating and nurturing a 'bigger than business' culture within a team of engineers. 

[10:28] A growth mindset pushes the limits of Additive Manufacturing through technological and adoption barriers.

[16:05] Markus requested a budget and resources be moved into AM technical design teams. 

[24:30] Siemens Energy is pushing the limits of pure additive-only designs for higher efficiency and lower emissions. 

Books Mentioned: 

●      Tribal Leadership: Leveraging Natural Groups to Build a Thriving Organization by Dave Logan, John King, and Halee Fischer-Wright

●      Mindset: The New Psychology of Success by Carol Dweck

Shareables: 

“I fundamentally believe in the mid-to-long run, a growth culture totally outperforms a performance culture.” — Markus Seibold, VP of AM, Siemens Energy & Material Solutions on The Additive Snack Podcast

“If we really want to accelerate the additive application development, we said, we need to, on purpose, put budget and headcount against additive applications. So, we created 30 new headcount requisitions.” — Markus Seibold, VP of AM, Siemens Energy & Material Solutions on The Additive Snack Podcast

“I can truthfully now claim that we [Siemens Energy] are the tipping point where additive is not only a technology push from a few but where it is getting toward a technology pull from many.” — Markus Seibold, VP of AM, Siemens Energy & Material Solutions on The Additive Snack Podcast

ASTM is an international standards organization that develops and publishes the standards that influence every step of the Additive Manufacturing process chain. These standards are not created in a silo. They are based on consensus and input from end-users, OEMs, government agencies, trade associations, and more. Therefore, individuals can play an active role in shaping standards and influence the future of Additive Manufacturing systems. 

Host Fabian Alefeld speaks with Mohsen Seifi, the Global Director of AM Programs at ASTM International about how standards are created, which standards are important to the AM journey, and how you can and should get involved. 

Key Takeaways:

[1:38] Mohsen describes ATSM’s involvement in the AM process and current efforts of the organization. 

[6:22] How standards help the AM industry to accelerate and why it’s important for individual contributors to get involved.

[10:54] Key standards in the AM process chain. 

[22:07] Mohsen shares an example of how a standard has impacted the core of the AM process. 

[28:58] Best practices and tips and tricks for an AM Qualifications/Quality Engineer.

[31:18] Mohsen shares his background in material science and engineering and his journey to his current position as a Director of Global AM Programs.

Shareables: 

“Due to the nature of the standard development processes which are consensus-based and voluntary, the pace of a standardization is not rapid.” — Mohsen Seifi, Director Global AM programs, ASTM on The Additive Snack Podcast

“The success of any high impact technology requires consistency, quality, repeatability, and ultimately scalability.” — Mohsen Seifi, Director Global AM programs, ASTM on The Additive Snack Podcast

“In the AM process, you have two main choices: you can either sit back and wait for the standards to be developed and to become available, or you can roll up your sleeves and contribute to the development and influence the direction.” — Mohsen Seifi, Director Global AM programs, ASTM on The Additive Snack Podcast

The Additive Snack Podcast is brought to you by EOS.

Additive Manufacturing (AM) of parts can take many shapes, from steel parts on trains to coat hangers, from rugged tools on tactical vehicles to components on electric supercars. That's a wide variety of applications but no matter the industry and no matter the use case, there are consistent best practices to help you identify your first AM part. You also need to consider how to select the best AM technology for your needs, how to choose the materials you want to use, and how to scale up your AM production.

Host Fabian Alefeld welcomes an all-star guest panel to share their expertise on the past, present, and future of AM. Stefanie Brickwede, Head of AM at Deutsche Bahn, John Wilczynski, Executive Director of America Makes, and Florian Lassan, Senior Business Development Manager of 3YOURMIND offer insights for the next generation of AM parts and applications.

Key Takeaways:

[1:53] Stefanie describes her roles and how MGA works to lower the hurdles of AM.

[3:23] John describes the goal of America Makes and his role in the organization.

[5:20] Florian describes the 3YOURMIND business model.

[6:55] How John discovered his first AM parts and how he calculated the total ownership costs.

[11:34] Convincing colleagues to adopt 3D printed parts was one of Stefanie’s first challenges at Deutsche Bahn.

[15:37] Florian’s group was tasked to design a control part for an electric supercar.

[18:40] Strategies for success in finding AM parts should mirror the overarching corporate strategies of an organization.

[24:45] Advice about how to implement AM into a supply and value chain.

[31:40] Stefanie details the process Deutsche Bahn created to accelerate the printing of parts to 25,000.

[34:25] The importance of specifications and standards when scaling from conventional to additive manufacturing.

[42:11] Advice from Florian and Stefanie about integrating AM strategies into an existing organization and convincing nonbelievers to use the technology.

Shareables: 

“How do we get more people to understand where it fits, how it fits, where to use it, when not to use it? We do it primarily through the three main pillars of our organization. Those are the development of technology, development of the educational or kind of workforce community, and development of the ecosystem meaning it’s the community that's ultimately going to take the technology and do something with it.” — John Wilczynski, Executive Director, America Makes on The Additive Snack Podcast

“The next parts we printed were metal and this is really crucial because we really had problems to convince our colleagues in the maintenance sides that 3D printing is a technology you can rely on and as much as something to print the Star Wars figurines.” — Stefanie Brickwede, Head of AM, Deutsche Bahn on The Additive Snack Podcast

“Manufacturing a tool for injection molding for such a low number of parts does not make sense. It was a good use case for additive manufacturing to manufacture that component. So, we optimized the design to cool this electric component and we used the freedom of design with additive to put some lightweight design for the part.” — Florian Lassan, Sr. Business Development Manager, 3YOURMIND on The Additive Snack Podcast
 

The Additive Snack Podcast is brought to you by EOS.

Post-processing is more than just the final finishing of a part. It needs to be integrated into the design phase of a project. In this episode, we dive into post-processing and finishing systems. It's a step that can add incredible value to your 3D printed product if done correctly. Many companies consider post-processing to be an afterthought, or they ignore it until it's too late and it is a big mistake because post-processing is such a vital part of any successful additive manufacturing initiative.

CEO and Co-founder of DyeMansion, Felix Ewald and host Fabian Alefeld discuss why post-processing is a big value driver for 3D printed products, the dreaded triangle of complexity, the post-processing options you should consider on your additive manufacturing journey, and how to develop application-specific post-processing workflows to exactly match the requirements in different industries and applications.

[1:37] DyeMansion’s first endeavor was a disappointment that ultimately led the organization to where it is today.

[4:40] Post-processing changes the game when it comes to 3D printed eyewear frames.

[6:37] The triangle of complexity is design, print and material, and finish.

[7:52] Felix takes a deep dive into post-processing technologies.

[15:13] The three ways to get color for consumer applications.

[17:44] How developers can ensure high-quality, reproducible results.

The Additive Snack Podcast is brought to you by EOS.

This episode is an example of how organizations can use additive manufacturing to its fullest benefit, such as customized parts, complex structures, and small batch sizes. We discuss the opportunity of understanding the limits of current manufacturing methods to create a high-performing product, offers a better user experience, is swiftly created, and is potentially more affordable than existing products. 

Chief Product Officer, Katie Brandeau describes how Fitz Frames has revolutionized the eyewear market using AM. Fitz created a face-scanning app that automatically creates the perfect fit for their 3D-printed glasses. It is a unique approach to product design that combines full customization with style in very little time.

[1:49] Katie describes her journey from R&D at Disney to Chief Product Officer of Fitz Frames. 

[4:26] Fitz Founder, Heidi Hertel recognized a need in the children’s eye care market and created a solution that included additive manufacturing.

[11:13] Guidance for engineers who want to know if an additive manufacturing solution is right for their application. 

[17:28] Disassembling the historical product design process was the key to reinventing the design process and integrating additive manufacturing.

[21:29] Katie describes an example where Fitz integrates the scan to print features to create truly customizable products in very little time.

[27:58] Creating a non-breakable hinge for kid’s glasses is an ingenious way Fitz Frames is disrupting the market and revolutionizing the eyewear industry.

[31:32] Considerations and mistakes companies make when incorporating additive manufacturing into the design process and product creation.

The Additive Snack Podcast is brought to you by EOS. 

Digital Transformation and Industry 4.0 are phrases that have dominated every industry on the planet for the past few years. But what exactly do they mean and how do they apply to real-world manufacturing? In this episode, we take a deep dive into the state of the art capabilities of today's additive manufacturing, the smart way to begin your digital transformation journey, and how to see through the buzzwords and focus on the practical benefits.

Co-founder and CEO of Link3D, Shane Fox helps us demystify the entire concept of digital transformation. Link3D works on the frontlines of the digital transformation journey. They partner with organizations to help them optimize their additive manufacturing workflows. 

[2:14] Link3D will focus on client solutions that allow them to move into a predictive state of manufacturing. 

[5:48] Creating a digital transformation strategy for additive manufacturing.

[12:53] Build a team that shares the same long-term vision for a digitized production environment.

[14:59] The importance of looking beyond the machines to shifting infrastructure from on-premise to cloud computing.

[22:36] Link3D considers the full value stream of the production environment.

The Additive Snack Podcast is brought to you by EOS.

Additive Manufacturing has been predominantly closed away in Research and Development departments for some time. But, as timely, justified additive manufacturing solutions emerge it is time for many companies to move from prototype to production. The chain of processes leaders implement now will affect the future use of industrial 3D printing within an organization.

In this episode, Chief Digital Officer of the medical and mobility powerhouse, Ottobock, Güngör Kara shares key insights about team building, implementing additive manufacturing, how organizations can create radical innovations, and the greatest challenges leaders face when moving additive manufacturing from prototype to production phase. 

Key Takeaways:

[1:05] Three key learnings of additive manufacturing implementation.

[4:02] Creating an additive manufacturing team must also include the problem and solution teams.

[6:58] The initial rapid prototyping phase requires C-level attention and support.

[9:13] The greatest challenges of moving additive manufacturing out of prototyping and into production.

[12:37] Leaders must push the limits of their team to create radical innovation.

[18:05] The two dimensions of scaling from one product to multiple products.

The Additive Snack Podcast is brought to you by EOS.

Additive Manufacturing has re-written many rules of product and part design. It has helped to improve part performance, cost of parts, and sustainability, all via design innovation. Engineers have the ability to creatively re-invent manufacturing from the ground up. Given this new freedom in the design process, what is the best way for an organization to capitalize and exploit the possibilities?

In this episode, Founder and CEO of the engineering software company, nTopology, Brad Rothenberg, shares the key elements to unlock the full potential of 3D printing. He discusses the ability of software to re-shape the future of product design, the innovative tools that allow designers to replace grunt work with creativity, and what not to do when designing products for additive manufacturing. 

The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:01] How nTopology’s engineering software fills the void in additive manufacturing design tools left by traditional manufacturing systems.

[5:58] The creative role of the human engineer in the design process of additive manufacturing.

[11:24] What not to do when creating products using additive manufacturing.

[20:03] Brad Rothenberg shares a fascinating example of how new design tools and human creativity developed an application for the airforce that would not have been possible in the past.

[24:23] Tips for engineers to accelerate design and engineering efforts.

[27:22] Software allows engineers to build a re-usable knowledge base of design capabilities.

[29:43] Brad shares his thoughts on where additive manufacturing will be in 5 years and how engineers can leverage their expertise.

Bradley Rothenberg is the founder and CEO of nTopology, an advanced software company based in New York City that focuses on enabling engineers to design, manufacture and ship high-performance products in the least amount of time. nTopology’s breakthrough computational-modeling technology unifies geometry and simulation results into finely tuned manufacturing models, supporting engineers as they collaborate to develop lightweight, optimized parts with functional requirements built right in. Bradley studied architecture at Pratt Institute in Brooklyn, New York, and has been developing computational design tools for advanced manufacturing for the last 10-plus years.

The factory of the future will be a blend of traditional manufacturing and additive manufacturing. In fact, additive manufacturing is on track to take one percentage point of the $250-350 billion dollar manufacturing market by complementing existing technologies with additional capabilities.

In this podcast, we examine the big picture of additive manufacturing, the value it can bring to your organization, the best ways to start your additive manufacturing journey, and how additive manufacturing can improve your competitive advantage. This conversation is a ‘state of the union’ for additive manufacturing. We examine where the industry is right now, how additive manufacturing can immediately meet industry needs, and the future integration of additive manufacturing into the traditional manufacturing market.

The Additive Snack Podcast is brought to you by EOS.

Wilderich Heising is a core member of Boston Consulting Group's Operations Center and a leader of BCG's manufacturing and supply chain work. Wilderich has worked with clients on manufacturing and supply chain strategy and network optimization, as well as advanced manufacturing topics such as additive manufacturing/3D printing, digitization of operations and Industry 4.0.

Brought to you by global additive manufacturing leader EOS, Additive Snack delivers the expert insights, interviews, and real-world stories that help you and your business achieve growth as well as success through additive manufacturing. 

I’m Fabian Alefeld, the host of Additive Snack and I lead the Additive Minds consulting team for EOS in North America. For years, we’ve helped businesses of all sizes explore the possibilities of AM and achieve success. Now we want to help you. 

Additive Snack is a forum for expert insights, best practices, and common mistakes to avoid on your AM journey. It’s no marketing B.S. and no product pitches. Just the education, inspiration, and information you and your organization needs to drive business growth – one step at a time. 

We know AM can be confusing. We know the path forward can be complex. Additive Snack is here to bring clarity to the chaos.

Get ready to feed your AM knowledge and find your path to success.