Layered Insights | A 3D Printing Podcast

Alex Orphanos & Matthew Guy

Layered Insights is a podcast about the real-world evolution of 3D printing—from hobbyist roots to industrial applications. Hosted by Alex (AG3D) and Matt (Niche 3D), two makers-turned-entrepreneurs, the show explores the tools, challenges, and breakthroughs of additive manufacturing. Whether it's scaling from prototypes to production, designing for real-world performance, or printing Iron Man helmets in your garage, each episode peels back a new layer of insight. Expect technical depth, honest stories, a bit of banter, and a whole lot of plastic.

Episodes

  1. 11/25/2025

    FORMNEXT 2025 Layered Insights on 3D Printing News from Germany | Part 1

    We're back for a Pop-Up Two-Part Episode to review the most exciting 3D Printing tech and innovations at FormNext in Germany this year. Matt & Alex share their favorites, from the latest reveals of the Prusa x Bondtech IDEX multi-material changer, some massive and impressive parts, to big ideas like adaptive heating which could now be possible thanks to advances like IDEX Lots to discuss! We'd love to hear what you thought about FormNext 2025 and what you're most looking forward to seeing hit the market. Part 2 releasing soon Links: Alexander G. Orphanos | AG3D: http://ag3d-printing.com Matthew Guy | Niche 3D LLC: http://Niche3D.io http://Niche3D.store

    42 min

  2. 10/26/2025

    Print 1 Layer 8: Digital Factories of the Now & Future vs Traditional Manufacturing & Business

    Alex and Matt discuss the evolution of manufacturing from traditional factories to digital factories, emphasizing the transformative impact of 3D printing. They highlight the inefficiencies of storing and shipping physical products, contrasting it with the digital factory's on-demand manufacturing and reduced storage needs. They note the benefits for small businesses, including lower overheads and the ability to print and ship directly to customers. They also discuss the potential for digital manufacturing to revolutionize supply chains, reduce real estate costs, and provide unique, customizable products. The conversation touches on the importance of making 3D models and digital files widely available for manufacturing. Links: Alexander G. Orphanos | AG3D: http://ag3d-printing.com Matthew Guy | Niche 3D LLC: http://Niche3D.io http://Niche3D.store

    36 min

  3. 10/19/2025

    Print 1 Layer 7: When the Worlds Break, We 3D Print! Pandemic, Tariffs, Space & The Battlefield

    3D Printing in Crisis & Chaos | Tariffs Pandemics The Battlefield & Outer Space! On this episode of the podcast Alex & Matt discuss the role of 3D printing during the pandemic and its potential in chaotic situations. During the pandemic, 3D printing helped alleviate shortages of masks and ventilators by enabling people to print essential equipment at home and for others.  The conversation shifts to the impact of tariffs on manufacturing, highlighting how 3D printing can bypass these costs and provide quick, custom solutions. Matt & Alex also explore the future of 3D printing in harsh environments, such as space and the battlefield, emphasizing its potential to revolutionize manufacturing and supply chains.  Links: Alexander G. Orphanos | AG3D: http://ag3d-printing.com http://store.stan/ag3dlabs Matthew Guy | Niche 3D LLC: http://Niche3D.io http://Niche3D.store Timestamps: 00:00 3D Printing During the Pandemic  03:46 Challenges and Innovations in 3D Printing 05:57 Impact of Tariffs on 3D Printing 11:50 Opportunities for 3D Printing in Various Industries 22:52 Future of Manufacturing and 3D Printing

    35 min

  4. 10/12/2025

    Print 1 Layer 6: Cosplay & 3D Printing | Our Favorite Makes & Techniques

    Alex and Matt discuss the growing popularity of 3D printing in cosplay, highlighting their experiences with their own various projects. Matt shares his Iron Man helmet project, which required 15 parts and extensive finishing work, including sanding and painting. Alex talks about his Mandalorian helmet, which was printed in one piece with minimal supports, and his Star Man helmet, which gained attention for its unique design. They also discuss the benefits of using advanced materials like TPU for durability and the potential for 3D printing to revolutionize cosplay by making complex designs more accessible. This is a great episode to do in October as Halloween will be here soon! If you are looking to get into cosplaying your own 3D printed costume - or need some help making one - reach out to either Alex or Matt below! We'd love to help!   Links: Alexander G. Orphanos | AG3D: http://ag3d-printing.com   Matthew Guy | Niche 3D LLC: http://Niche3D.io http://Niche3D.store Timestamps: 00:00 Cosplay and 3D Printing: Introduction and the Big Picture 03:23 Challenges and Learning Experiences in Cosplay 3D Printing 06:59 Advanced Techniques and Materials in Cosplay 3D Printing 15:54 Group Cosplay and Functional 3D Printed Items 22:08 Unique and Creative Cosplay Projects 50:13 Final Thoughts and Future Prospects

    59 min

  5. 10/06/2025

    Print 1 Layer 5: Why Design Skills Still Matter in the Age of AI and 3D Printing

    Alex and Matt dedicate a whole episode to discussing the power of Design skills, particularly CAD design in making parts, and how the skillset should last and have value in the face of economic and technological uncertainties with AI and the state of the economy. Our hosts discuss Design in various industries, including 3D printing, and the growing demand for 3D models. Highlighting the differences between CAD and other 3D modeling tools like Blender, noting the systematic nature of CAD and the artistic flexibility of apps like Blender (which both hosts are in awe of). They also discuss the challenges of designing for manufacturability and the potential of AI in design, but still admitting that hands-on experience and adaptability remain critical for the near future of making parts. Links: Alexander G. Orphanos | AG3D: ag3d-printing.com stan.store/AG3Dlabs Matthew Guy | Niche 3D LLC: Niche3D.io Timestamps: 00:00 Design Skills in the Age of AI and 3D Printing 02:17 The Importance of Good Design 05:00 Challenges and Limitations of Different Design Tools 06:30 The Role of Design in Manufacturing and Engineering 07:17 Design for Different Manufacturing Methods 21:20 The Art of Designing for User Experience 31:07 The Impact of AI on Design 45:29 The Future of Design and Manufacturing 53:06 Practical Advice for Aspiring Designers 54:01 Closing Thoughts and Contact Information

    55 min

  6. 09/28/2025

    Print 1 Layer 4: 3D Printing Tool Time! Our Essentials & The Ones That We Wish We Had

    Alex and Matt share "tool time" advice on various 3D printing tools they use alongside their 3D Printer. They discuss tools for maintenance, post-processing, and support removal, and more. Matt & Alex also share cost-effective options, as well as high-end tools that get the job done. We close out discussing the tools we wish we had and how the right tool, no matter what it is, is invaluable to reduce labor and create better parts - faster! Matt's blog on his essential tool for 3D printing (with affiliate links): https://www.niche3d.io/thenichenotes/essential-tools-for-3d-printing Links: Alexander G. Orphanos | AG3D:  ag3d-printing.com stan.store/AG3Dlabs Matthew Guy | Niche 3D LLC: Niche3D.io 00:00 Introduction to Layered Insights Podcast 00:43 Importance of Tools in 3D Printing 02:37 Cost-Effective Tools for 3D Printing 04:16 Premium Tool for Resin 3D Printing 08:50 Tools for Part Post-Processing 15:57 Tools for Support Removal 23:17 Tools for Prototyping 28:27 Tools for Maintenance 35:08 Future Tools We WISH We Had 41:12 Final Thoughts

    43 min

  7. 09/21/2025

    Print 1 Layer 3: From Hobby to Hustle | Evolving with 3D Printing for Business

    Alex and Matt discuss the evolution of 3D printing: Going from hobbyist to hustling for yourself or working for a business using a 3D Printer. The importance of hands-on experience, tinkering, and starting with a more challenging 3D Printer to start can prime great growth for anyone interested in 3D printing. Alex highlights the value of 3D printing in business, citing his experience in aerospace and the benefits of rapid prototyping. Matt shares his journey from hobbyist to founding a 3D printing business, stressing the need for problem-solving and adaptability. While both hosts emphasize that leveraging 3D printing's flexibility and speed to innovate and inexpensive up-front costs (compared to injection molding) can make Additive Manufacturing a valuable asset to a company or individual when making parts for business. If you have a 3D printer and want to go to the next level, this is the podcast for you. Learn about all the ways you can use your 3D printing skills to make money - either for yourself or for a company. Links: Alexander G. Orphanos | AG3D Labs: ag3d-printing.com Matthew Guy | Niche 3D LLC: Niche3D.io Timestamps: 00:00 Getting Started with 3D Printing & Evolving to the Next Level 03:08 Choosing the Right 3D Printer for your Path 06:47 3D Printing Skills in the Industry/Workplace 11:20 The Role of 3D Printing in Business 19:55 Starting a 3D Printing Business 25:24 Balancing Hobbyist & Professionals Skills in 3DP 29:48 The Future of 3D Printing & the Additive Community 34:40 When 3D Printing Competes with Injection Molding/High-Volume Part Making 44:04 Alex's Story about Making his Own Warturtle As a Kid  45:12 Final Thoughts On How To Get Into 3D Printing

    50 min
  8. Print 1 Layer 2: From Prototype to Production | Making 3D Printing Work at Scale w/ Matt & Alex

    09/14/2025

    Print 1 Layer 2: From Prototype to Production | Making 3D Printing Work at Scale w/ Matt & Alex

    Alex and Matt discuss the transition from prototyping to production with 3D printing. Emphasizing the importance of design FOR additive manufacturing (and not just printing any file you found on the internet). They highlight the power of iterative prototyping to refine designs and the variety of plastics available for 3D printers, and what they are good at. They close the podcast out discussing the big picture ideas of producing parts for someone like managing expectations, part quality, and the amount of work it really take to produce parts in bulk at the quality the customer is happy with. A great introduction to the grind that is 3D printing and making lots of parts. It's VERY rewarding...but it's also no picnic. If this episode get's you excited about making parts with a 3D printer, you might be built for this life. Join us! Links: Alexander G. Orphanos | AG3D Labs: ag3d-printing.com Matthew Guy | Niche 3D LLC: Niche3D.io Timestamps: 00:00 Scaling from Prototyping to Production in 3D Printing  02:21 Designing for Additive Manufacturing 03:00 Challenges in Prototyping and Production 17:33 The Power of Material Selection and Print Settings 33:49 Post-Processing and Surface Finish 40:52 Industrial and Specialized Materials 44:08 Customer Communication and Expectation Management 44:56 Prototyping and Production Workflow 45:44 Training and Maintenance for 3D Printers 47:15 Final Thoughts and Future Directions

    49 min
  9. Print 1 Layer 1: Matt & Alex Reveal Their FIRST 3D Printers & 3D Printing Origin Stories

    09/07/2025

    Print 1 Layer 1: Matt & Alex Reveal Their FIRST 3D Printers & 3D Printing Origin Stories

    Alex and Matt discuss their experiences with 3D printing, highlighting their backgrounds and current roles. Alex, who has been 3D printing for seven years, runs AG3D Printing, a service focusing on part success and storytelling. Matt, with six years of experience, recently went full-time with his own company, Niche 3D, to help companies adopt 3D printing. They share their first printers—Alex's Rigidbot Big and Matt's Prusa MK2S—and the challenges and lessons learned from them. Both emphasize the importance of hands-on experience and the evolving capabilities of 3D printing technology, including its potential to revolutionize manufacturing and reduce waste and emissions. Links: Alexander G. Orphanos | AG3D Labs: ag3d-printing.com Matthew Guy | Niche 3D LLC: Niche3D.io  Timestamps: 00:00 Introduction to Layered Insights Pilot Episode 00:42 Alex of AG3D's Origin Story in 3D Printing 01:39 Matt of Niche 3D's Origin Story in 3D Printing 03:34 Matt's first year with Niche 3D Full Time - How it's Going 04:52 When you Love 3D Printing at Work & at Home... 05:58 Our FIRST 3D Printers & Early Experiences 12:04 Transitioning a Hobby to Professional 3D Printing 13:08 Challenges and Opportunities in the 3D Printing Industry 14:04 The 'MakerBot' Era and the Early Days of 'everyone's first 3D Printer' 18:35 The Age Before Ample Amazon 3D Printing Supplies & Spare Parts... 20:04 Alex Storytime: How I learned about manufacturing & $ from Ed the Toolmaker 21:22 Low vs. High Volume Part Production: 3D Printing vs. Injection Molding & more 22:11 There are STILL so many people who haven't learned about 3D printing or its potential 27:10 Our Shared Mission for Making 3D Printing Accessible to Everyone 29:40 Q: "What is the total number of printers that you have currently?" 30:17 How to Follow, Support, and Work With Matt & Alex

    32 min
  • 9 Episodes

About

Layered Insights is a podcast about the real-world evolution of 3D printing—from hobbyist roots to industrial applications. Hosted by Alex (AG3D) and Matt (Niche 3D), two makers-turned-entrepreneurs, the show explores the tools, challenges, and breakthroughs of additive manufacturing. Whether it's scaling from prototypes to production, designing for real-world performance, or printing Iron Man helmets in your garage, each episode peels back a new layer of insight. Expect technical depth, honest stories, a bit of banter, and a whole lot of plastic.

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