Additive Snack

EOS

Join host Fabian Alefeld and a range of guests as they discuss all things additive manufacturing (AM) and 3D printing news, with interviews and real-world stories to educate and entertain. Each episode, Fabian talks to AM experts, professionals in specialist fields, and 3D printing users from all walks of life to deliver a well-rounded view on the state of AM. Cut through the confusion surrounding polymer and metal additive manufacturing solutions with our digestible, down-to-earth discussions that deliver insights into common mistakes and best practice tips so you can get a clear understanding of AM — layer for layer. Whether you’re curious about 3D printing technology for the aerospace industry, a deep dive into post processing, or applications of injection molding — we leave no spare parts behind. We want to provide you with the additive insight needed to stay laser focused and leverage every opportunity 3D printing materials have to offer. Join us for an Additive Snack and we’ll help you and your business achieve growth and success through the latest developments in AM. No marketing B.S. and no product pitches. Just the education, inspiration and information you and your organization need to drive business growth, brought to you by global AM leader EOS. Get ready to feed your AM knowledge and find your path to success!

  1. 1日前

    The AM Sasquatch: Challenging AM Qualification with Math, Physics, & AI

    Fabian Alefeld welcomes back Harshil Goel, founder and CEO of Dyndrite, to discuss how current additive manufacturing (AM) qualification practices limit advanced laser powder bed fusion toolpaths by locking variables such as software, machine, strategy, layer height, and material. Harshil reviews MQ, IQ, OQ, and PQ, noting cost and rigidity increase toward part qualification.  They discuss Dyndrite’s roles in multiple America Makes efforts: AI4AM to reduce the specimen counts needed for material allowables (starting with 17-4PH) using improved statistical methods; DeltaQual 2.0 to enable “bracketed qualification” so parameter changes within a defined process window don’t retrigger requalification (including varying layer heights within a part); and Gotham to transfer scalable, qualified parameter approaches across different machines and sizes using materials like Scalmalloy.  Harshil describes “Sasquatch,” a physics-based KPV framework using ratios (e.g., energy density, enthalpy, melt pool dimensions) to bound process windows and increase confidence without relying solely on sensors or simulation, and highlights software and AI accelerating DOE and parameter iteration with a target program timeline of about two years. 01:34 What Dyndrite Builds 02:11 Why Qualification Blocks Innovation 03:58 IQ OQ PQ MQ Explained 08:22 PQ Locks Everything Down 09:00 America Makes Program Overview 09:57 AI4AM Materials Allowables 12:39 Process Windows Not Fixed Params 14:57 Delta Qual 2 Bracketed Qual 17:38 Partners Sensors And Confidence 19:25 Sasquatch New KPVs 25:33 Gotham Scaling Across Machines 27:07 Future Less PQ More Reuse 28:39 Industry Impact Of Faster Qual 29:52 Customer Owned Parameters 30:54 Additive As Moat 32:13 Microstructure Driven IP 33:12 Selling Machine Control 34:31 Breaking Vendor Silos 35:36 Two Year Timeline 37:57 Risks And Adoption 41:23 Software As Glue 42:11 AI Accelerated DOE 45:34 Math Meets Empiricism 49:48 Future Outlook Wrap

    The AM Sasquatch: Challenging AM Qualification with Math, Physics, & AI

  2. 8月25日

    AM as a Moat: How Annihilator Created a Competitive Advantage in Broadhead Manufacturing

    Fabian Alefeld interviews Brandon Brodie, co-founder and CEO of Annihilator Broadheads, about how an Idaho elk hunt and a lost bull sparked a new broadhead concept sketched by Brandon’s future partner Micah. They describe turning the 2D sketch into plastic CAD prototypes via Boise State, a makeshift “wind tunnel” test using Instant Pot steam, and early performance goals of flight, penetration, durability, and lethality. Field and improvised tests (steel drum, long-range accuracy, animal kills) plus third-party fluid dynamics modeling suggested Annihilator’s design created unusually large high-pressure and low-tension effects.   After major supply failures with investment casting and metal injection molding - causing shortages, high scrap rates, and lost dealers - Brodie brought manufacturing in-house, adopting metal laser powder bed fusion, improving repeatability and enabling new geometries like the Katana. He outlines ongoing innovation, potential adjacent products, and plans to leverage Annihilator’s additive capabilities for partnerships and contract manufacturing.  02:26 Elk Camp Origin  06:43 Sketch to Prototype  11:36 Instant Pot Wind Test  14:44 Performance Pillars  18:41 Steel Drum Proof  22:45 Real Hunt Validation  26:45 Fluid Dynamics Breakthrough  30:41 Engineering Led Marketing  33:32 Manufacturing Growing Pains  34:27 Industry Award Surprise  35:53 COVID Demand Crunch  36:54 Casting Supplier Failures  39:40 MIM Tooling Disaster  42:30 Additive Breakthrough  46:35 Learning Metal Printing  49:55 Repeatability and Materials  52:56 Katana Broadhead Innovation  57:49 Scaling R&D Team

    AM as a Moat: How Annihilator Created a Competitive Advantage in Broadhead Manufacturing

  3. 8月18日

    AI Is Getting Hot: Can Additive Manufacturing Help Cool It Down?

    Host Fabian Alefeld interviews Professor PS Lee, Head of National University of Singapore Mechanical Engineering & Program Director of STDCT, and founder of CoolestDC, about heat as a key constraint in AI infrastructure as data centers shift from CPU-heavy to GPU-dense systems with higher power density, hotspots, and bursty workloads. Lee explains why cooling must be treated as an integrated “chip to grid” system spanning cold plates, racks, CDUs, piping, controls, and operations, and discusses single-phase versus two-phase direct-to-chip liquid cooling and the added need for condensation in closed loops.   Professor Lee describes how additive manufacturing (AM) enables complex fin structures and unibody cold plates that reduce leakage risk, lower junction temperatures (~10°C), cut pumping power (60–70%+), and reduce material use, while requiring TCO evaluation. At NUS’s live testbed (22 liquid-cooled racks, ~500 kW), AM cold plates are being deployed and show promising thermal, power, and compute-performance improvements; future work includes two-phase cooling and broader system-level heat rejection, warm-water operation, and waste-heat reuse, plus a discussion of challenges and potential AM roles in space-based data centers.  02:13 Meet Professor Lee  05:26 Chip To Grid Cooling  10:22 Liquid Cooling Maturity  14:15 Two Phase Explained  18:12 Cold Plate Tradeoffs  20:40 AM Unibody Cold Plates  24:41 Benchmarking AM Gains  30:18 AM For CDUs  34:13 Inside STDC Testbed  38:09 Reliability And Leakage  39:00 Next Phase Roadmap  42:31 Orbital Data Centers

    AI Is Getting Hot: Can Additive Manufacturing Help Cool It Down?

  4. 7月21日

    Inside GM's Additive Industrialization Center with Ante Lausic

    In this episode, Fabian Alefeld sits down with Ante Lausic, Lead Process Engineer at General Motors' Additive Industrialization Center (AIC), to explore what it takes to successfully scale additive manufacturing (AM) in the automotive industry. Ante explains why automotive manufacturing demands more than innovative technology - it requires AM-native designs, cost-effective production, automotive-qualified materials, and repeatable processes capable of supporting high-volume manufacturing. He also shares how GM has evolved from using AM primarily for rapid prototyping to establishing the Additive Industrialization Center in 2020 to evaluate new technologies, validate production readiness, and strengthen collaboration across the supply chain. The conversation highlights real-world production applications, including the Cadillac Celestiq, which incorporates more than 130 AM components, such as a safety-critical binder-jetted stainless steel seatbelt guide and aluminum steering wheel trim. Ante also discusses the rapid growth of additive manufacturing for tooling, including die-casting inserts, plant fixtures, and end-of-arm tooling, and offers his perspective on where the technology is delivering the greatest value for automotive manufacturers today. 01:56 Scaling AM in Automotive 05:10 Value and Cost Reality 07:27 GM Additive Center Origins 11:02 Educating Engineers and Suppliers 14:34 Celestiq AM Success Stories 19:44 Supplier Freedom and Standards 23:00 Tooling Inserts Big Wins 27:50 End of Arm Tooling Growth 29:36 Motorsports and F1 Links 32:10 Aftermarket Digital Warehousing 33:39 Materials and PPAP Hurdles 36:14 PPAP Explained Simply 38:43 Rethinking Qualification Costs 41:07 Scaling to Corvette Volumes

    Inside GM's Additive Industrialization Center with Ante Lausic

  5. 7月14日

    Why AM and Orthotics & Prosthetics are the Perfect Fit

    Fabian Alefeld interviews certified prosthetist/orthotist and EastPoint Prosthetics VP Brent Wright about his career path into O&P, his shift from being anti-digital to adopting scanning and additive manufacturing, and the impact on patient care and global access. Wright describes traditional fabrication workflows (casting, plaster positives, vacuum forming thermoplastics for orthoses, and carbon fiber/resin layups for prostheses) as artistic but time-consuming, hazardous, and lacking records.  His digital journey accelerated after a Guatemala trip with Life Enabled highlighted the need to scale care; he focused on scanning, digital modification, and later powder-bed fusion, moving toward SLS with materials like PK5000 and TPU. He emphasizes pressure casting for prosthetic sockets, the value of digital records for insurance, and how AM can change socket “dynamics” to improve comfort and heal wounds.  The discussion also covers RADii’s data-driven fitting approach, Life Enabled’s mix of traditional and 3D-printed solutions (including pediatric feet), modular “kit” concepts for developing regions, and barriers to sensors/actuators in the US due to reimbursement. 02:33 Brent Origin Story 09:30 Why Go Digital 11:17 Scaling Global Access 17:32 Traditional O&P Workflow 20:02 Casting And Fabrication Steps 24:07 Digital Workflow And Scanning 33:22 Benefits Of Digital Records 36:36 Flexible Liner Heals Wound 40:47 RADii Data Meets Craft 46:06 Life Enabled Model 01:01:50 Democratizing via Manufacturing 01:08:01 Sensors vs Simplicity

    Why AM and Orthotics & Prosthetics are the Perfect Fit

  6. 7月7日

    AM at a Crossroads: Incodema3D Proves What's Possible at Scale

    Fabian Alefeld sits down with Sean Whittaker, founder, president, and CEO of Incodema3D, to discuss the company's journey from a sheet metal prototyping business to one of North America's largest metal additive manufacturing operations. Sean shares why he invested in metal AM early, how Incodema3D built a production-first business model, and what it takes to scale additive manufacturing beyond prototypes. The conversation explores the evolution of Laser Powder Bed Fusion (LPBF) technology, the importance of vertically integrated manufacturing, and how improvements in machines, materials, software, and Design for Additive Manufacturing (DfAM) are making production at scale a reality. Sean also discusses growing demand driven by reshoring, defense, aerospace, and energy applications, Incodema3D's specialization in aluminum thermal management components and high-volume Inconel production, and how AFM Capital's investment is accelerating expansion through new equipment, automation, and future U.S. manufacturing sites. Episode Chapters 01:41 Sean's Origin Story 05:13 Taking the Leap into Metal Additive Manufacturing 07:05 From Prototypes to Production 08:07 The Advantage of Vertical Integration 10:54 The Maturity of Additive Manufacturing and DfAM 15:46 Thermal Management, Inconel, and Consumer Applications 19:21 Defense, Energy, and Replacing Cast Components 21:28 Accelerating Growth with AFM Capital 25:49 Cycle Times, ROI, and Production Flexibility 30:07 Automation and Building the AM Workforce 34:50 Reshoring, Expansion, and the Future of Production 39:50 Wrap-Up

    AM at a Crossroads: Incodema3D Proves What's Possible at Scale

  7. 6月23日

    AM Rocket Engines and Space Nuclear Power with Omar Mireles

    Fabian Alefeld interviews Omar Mireles, Director of Manufacture and Materials at Space Nuclear Power Corporation (Space Nukes), about his career spanning NASA, Oak Ridge, and Los Alamos and how additive manufacturing (AM) reshaped space hardware development. Omar describes early exposure to SLS prototyping, graduate work in nuclear materials and propulsion, building nuclear materials labs at NASA Marshall, and later leading AM efforts for liquid rocket engines and refractory metals.   He explains how AM accelerates iteration, enables complex geometries, part consolidation, and weight reduction, and where traditional methods still dominate depending on production rate. The conversation covers refractory metal challenges (supply chain, oxygen sensitivity, post-processing, inspection) and nuclear reactor basics, generations, and regulatory barriers to AM adoption. Omar outlines Space Nukes’ goal of delivering safe, affordable, reliable power anywhere in the solar system, noting heat rejection as a key space constraint, Krusty’s 2018 test heritage, potential AM roles in heat exchangers, and an aggressive ~2-year flight timeline depending on regulation and mission.  02:26 Omar Early Motivation  03:08 NASA Co-ops and First AM  07:59 Stirling Radiation Research  20:07 Refractory Metals AM Lab  21:31 Los Alamos to Space Nukes  25:14 Did AM Change Space Race  31:46 Where AM Flies Today  37:41 Rocket Engines Print vs Traditional  41:15 Refractory Alloys Challenges  46:39 Where Refractories Make Sense  47:05 Will Refractory AM Grow  49:39 NASA Metal AM Handbook Origins  56:37 How Nuclear Reactors Work  01:13:02 Additive Manufacturing in Nuclear  01:18:31 What Space Nukes Builds  01:19:36 Why Space Nuclear Power Matters  01:25:20 Why Space Needs Nukes  01:37:47 Krusty Test Proof  01:41:18 Heat Rejection Challenge  01:49:25 Timeline and First Missions

    AM Rocket Engines and Space Nuclear Power with Omar Mireles

  8. 6月2日

    The Manufacturing Comeback: Dean Bartles on Defense, AI, and the Next Industrial Revolution

    Host Fabian Alefeld interviews Dean Bartles, President and CEO of the Manufacturing Technology Deployment Group (behind NCDMM, Advanced Manufacturing International, and America Makes), about manufacturing’s evolution, defense industrial base challenges, and additive manufacturing. Bartles recounts his career from shop-floor machining and industrial engineering to international defense manufacturing programs and 31 years through successive owners culminating in General Dynamics, then leading NCDMM and forming a parent organization to expand technology deployment. They discuss consolidation and contracting barriers that pushed small/medium firms out of defense, productivity gains from automation, reshoring momentum driven by tariffs and new investment, and workforce shortages and training pathways via trades, community colleges, and SME/Tooling U. Bartles highlights AI for process monitoring and adaptive control in laser powder bed fusion, the promise of low-cost desktop FFF for drones, the need for shared data and improved repeatability, and sustainability efforts including the Additive Manufacturing Green Trade Association.    00:00 Welcome and Guest Intro    02:54 Dean Manufacturing Origins    04:18 Global Defense Career Path    06:05 Leading NCDMM and America Makes    10:44 Defense Base Decline and Industry 4.0    18:14 Reshoring and Global Models    22:17 AI Capital and Process Control    35:25 Open Data and Repeatability Challenge    38:24 Defense Adoption and Drone Boom    44:08 Workforce Pathways and Community Colleges    50:04 Sustainability and Greener AM    54:27 Closing ABL Always Be Learning

    The Manufacturing Comeback: Dean Bartles on Defense, AI, and the Next Industrial Revolution
すべて見る（105）

予告編

番組について

Join host Fabian Alefeld and a range of guests as they discuss all things additive manufacturing (AM) and 3D printing news, with interviews and real-world stories to educate and entertain. Each episode, Fabian talks to AM experts, professionals in specialist fields, and 3D printing users from all walks of life to deliver a well-rounded view on the state of AM. Cut through the confusion surrounding polymer and metal additive manufacturing solutions with our digestible, down-to-earth discussions that deliver insights into common mistakes and best practice tips so you can get a clear understanding of AM — layer for layer. Whether you’re curious about 3D printing technology for the aerospace industry, a deep dive into post processing, or applications of injection molding — we leave no spare parts behind. We want to provide you with the additive insight needed to stay laser focused and leverage every opportunity 3D printing materials have to offer. Join us for an Additive Snack and we’ll help you and your business achieve growth and success through the latest developments in AM. No marketing B.S. and no product pitches. Just the education, inspiration and information you and your organization need to drive business growth, brought to you by global AM leader EOS. Get ready to feed your AM knowledge and find your path to success!

情報

  • クリエイター
    EOS
  • 配信期間
    20年 - 26年
  • エピソード
    105
  • 制限指定
    不適切な内容を含まない
  • Copyright
    © 2026 EOS
  • 番組のWebサイト
    Additive Snack

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