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Additive Snack — Technology
Additive Snack

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!

Copyright: © 2020 Fabian Alefeld

Latest Episodes:

Simulation as an Enabler: Pan Michaleris & Erik Denlinger on the Evolution of Additive FEA May 06, 2026

Show notes

Fabian Alefeld hosts Pan Michaleris, founder of PanOptimization (PanX), and Erik Denlinger, co-founder and chief engineer, to discuss the evolution and role of simulation and finite element analysis (FEA) in additive manufacturing. Pan shares his background as a Penn State professor and entrepreneur (including a prior company acquired by Autodesk) and explains how simulation helps reduce costly trial-and-error builds by predicting distortion, temperature, stress, buckling, cracking, and recoater risks, while moving toward closed-loop manufacturing-to-design workflows and property prediction. Erik outlines PanX’s commercial capabilities - fast thermo-mechanical simulation for very large parts, distortion compensation, and dwell-time optimization - and describes proof-of-concept work on controlling melt quality and hardness via parameter modulation. They cover adoption in aerospace/defense and new space, qualification implications, integration with build-prep workflows (e.g., EOS/Velosis), and cautious, validation-focused views on AI surrogate models.

00:00 Welcome and Episode Preview

01:13 Meet Pan and Erik

01:59 Pan’s Journey to PanX

03:59 Erik’s Origin Story

05:10 FEA History and the Elephant Test

08:32 Why Additive Needs Simulation

10:23 Closing the Design Manufacturing Loop

14:33 PanX Today Core Capabilities

17:30 From Distortion to Material Properties

20:25 Making Simulation Usable for Engineers

27:06 Workflow Integration and Automation

29:44 From Failures to Design

30:41 Who Uses PanX Today

32:41 Simulation for Qualification

35:17 Layerwise Parameter Control

38:51 Why FEA Is Hard

41:38 AI and Surrogate Models

46:53 Future Material Tailoring

48:37 Roadmap Workflow Integration

52:27 Closing Thoughts and Wrap

The State of AM in Asia Apr 10, 2026

Show notes

Host Fabian Alefeld speaks with Japan-based additive manufacturing consultant Peter Rogers about the state of additive manufacturing across Asia Pacific. Rogers contrasts Japan’s advanced but risk-averse manufacturing culture - strong in incremental optimization, with slower certification (notably medical) and limited defense budgets - with faster-moving but smaller markets like Australia/New Zealand, where mining drives demand for rapid, remote part supply. They discuss China’s manufacturing scale and government support, its growing dominance in desktop FDM, and how low-cost Chinese metal PBF machines can win and retain service-bureau business despite Western strengths in quality and productivity. Singapore is highlighted for academia and MRO, while Korea spans shipbuilding, semicon, automotive, and defense. Southeast Asia is still production-focused with limited local R&D, whereas India is rising as an English-speaking engineering and R&D hub for global OEMs. Both see lowering costs and AI enabling broader, consumer-facing AM applications.

00:00 Welcome and Guest Intro

01:49 Peter Rogers Background

03:32 Moving to Japan

05:12 APAC Additive Overview

09:23 China Manufacturing Dynamics

13:27 Reshoring and Kaizen Mindset

18:45 Traditional Skills vs Additive

20:57 Japan Nearing Inflection Point

25:06 Top APAC Applications

29:02 Japan Korea Industry Mix

30:31 China Scale And Funding

33:18 FDM Race To Bottom

34:27 Bambu Ecosystem Advantage

36:53 Metal AM Price Expansion

38:23 Chinese Metal Machines Case

40:30 Competing On Productivity

44:10 Southeast Asia Adoption

47:06 India RnD Powerhouse

49:46 Future Consumer Breakthroughs

52:40 Japan Pushing DED Limits

55:30 AI Lowers Barriers

57:13 Wrap Up And Farewell

From Fashion to Metal AM: Scaling Additive Manufacturing into Production Mar 25, 2026

Show notes

Host Fabian Alefeld interviews Erin Mastroni, President and founder of I3D Manufacturing (founded 2013), about building one of the largest additive-focused contract manufacturers and the industry’s shift from prototyping to production. Mastroni describes moving from fashion retail and trend forecasting to an MBA in sustainable business, spotting production AM as a key trend, and launching a metal powder bed fusion business in Oregon with limited traditional manufacturing experience. She recounts early funding challenges, using SBA/New Market Tax Credits, and landing Blue Origin as an early customer, which helped establish I3D as a fast-moving development partner known for tackling difficult materials like titanium and new nickel alloys with EOS. I3D grew from 5 people and two machines to two campuses, ~30 machines, and 54 employees, is launching an internal “I3D Academy,” navigated a severe COVID revenue drop without layoffs, and was acquired in 2023 by BTX Precision (L Squared Partners), expanding into turnkey CNC and broader capabilities while discussing PE’s role, production scalability, and emerging AI opportunities.

00:00 Podcast welcome

01:47 Fashion to additive

04:27 Funding and mission

06:52 Blue Origin breakthrough

08:27 Becoming a dev partner

12:19 I3D today scale

15:29 Growing talent academy

17:05 Growth phases and pandemic

20:22 Acquisition and turnkey expansion

22:06 Private equity tipping point

27:43 Private Equity Momentum

28:41 Flow Driven Applications

32:54 Supply Chain Use Cases

35:12 Scaling Production Know How

40:21 One Stop Shop Strategy

43:14 Customers Get Smarter

47:31 Next Wave Breakthroughs

53:03 AI In Additive Manufacturing

57:25 Closing Thanks

AI Update in Additive Manufacturing: Design, Process, Workforce and Industry impact Mar 04, 2026

Show notes

Fabian Alefeld hosts Duann Scott on the Editor Snack podcast to discuss how AI is evolving in additive manufacturing, moving from “AI-washing” and impractical text-to-mesh hype toward more capable tools using language models, visual language models, surrogate models, and emerging foundational models. Scott describes testing tools by trying to make them fail and highlights a recent success with the Raven plugin for Rhino/Grasshopper, which generated a parametric VESA mount and tripod adapter from minimal prompts, then iteratively added fillets and an isogrid structure and produced a printable part within hours. They discuss constraints like missing engineering training data and design intent, the promise of AI for toolpath and process optimization (including transfer of parameter knowledge across materials), and the role of the 3MF format in capturing toolpath and metadata to enable richer, searchable datasets. Scott previews CDFAM events in Barcelona, DC, and Tokyo and emphasizes that progress requires significant data work and investment.

00:00 Welcome and Guest Intro

02:18 AI Hype to Real Progress

04:13 Testing AI Design Tools

04:46 Data Gaps and Design Intent

07:15 Two Paths for AI Design

10:15 Raven Grasshopper Breakthrough

13:17 Pushing Parametric Complexity

20:28 Limits of Black Box Optimization

22:40 Toolpath and Material Transfer

26:18 Alloy Discovery and Qualification

28:05 3MF Role Teaser

28:18 3MF Format Overview

29:17 Smarter Toolpath Extensions

32:31 Metadata for AI Training

35:43 Data Ownership and Synthetic Data

39:59 AI Impact on Additive

44:10 Workforce and Reshoring

47:22 What Is CDFAM

49:49 CDFAM Audience and Format

51:43 DC Event and Government

54:05 Wrap Up and Thanks

Beyond the Printer: Automation’s Role in the Next Generation of AM Jan 27, 2026

Show notes

In this episode of the Additive Snack Podcast, host Fabian Alefeld is joined by Oliver Elbert, Head of Additive Manufacturing at Grenzebach, to discuss the pivotal role of automation in scaling additive manufacturing. They delve into Grenzebach’s extensive expertise in industrial automation and its recent ventures into additive manufacturing. The conversation covers the challenges and benefits of automating post-processing tasks, increasing equipment efficiency, and optimizing labor dynamics. They also explore notable projects like the Next Gen AM and the Polyline project, highlighting how automation can significantly enhance production availability and reduce manual intervention. Oliver provides insights into the integration of automated guided vehicles (AGVs), robots, and job exchangers in additive manufacturing, and discusses the future potential of fully automated production environments.

00:00 Introduction to Additive Snack Podcast

00:18 The Challenge of Automating Additive Manufacturing

01:07 Introducing Grenzebach and Oliver Elbert

02:22 History and Evolution of Grenzebach

06:33 Grenzebach’s Entry into Additive Manufacturing

08:31 The Slow Adoption of Automation in Additive Manufacturing

14:34 The Dual Setup Station and Its Impact

19:25 Automation Solutions for Various Industries

23:52 The Future of Automation in Additive Manufacturing

24:48 Challenges and Opportunities in Automation

34:13 The Role of Humanoids in Industrial AM

36:20 Conclusion and Future Outlook

How AM is Supporting the Grid Jan 22, 2026

Show notes

In this episode of the Additive Snack Podcast, host Fabian Alefeld welcomes Kristin Mulherin, the Director of Additive Manufacturing Technology at Hubbell Inc., to discuss the creation and development of an additive manufacturing center of excellence within a 150-year-old corporation. Kristin shares her extensive journey through various roles in the additive industry, from Northrop Grumman to HP, and her significant input in initiatives like Women in 3D Printing. She discusses Hubbell's historical background and the strategic decisions behind establishing the AM center, including technology choices, cost management, and internal education to drive innovation.

The episode covers specific applications, the challenges of shifting from prototyping to production, and the importance of cross-departmental education within the company to leverage the full potential of additive manufacturing.

00:00 Introduction to the Additive Snack Podcast

01:40 Meet Kristen Mulherin: A Journey in Additive Manufacturing

05:07 Kristen's Role at Hubbell Inc. and Industry Insights

06:11 Women in 3D Printing and Leadership

07:46 Building Hubbell Inc.’s Additive Manufacturing Center of Excellence

15:25 Technology Stack and Future Plans at Hubbell

19:30 Exploring New Opportunities in Additive Manufacturing

21:38 Balancing Cost and Lead Time in Additive Manufacturing

22:08 Value Drivers in Additive Manufacturing

Education, Investment & the Additive Workforce with America Makes - Part 2 Jan 06, 2026

Show notes

In the second part of this two-part episode series of the Additive Snack Podcast, host Fabian welcomes Dr. Edward Herderick, Director of Education and Workforce Development at America Makes, to discuss the maturation of additive manufacturing. They delve into the evolution of the technology, its impact on the industry, and the importance of specialized education to foster a capable workforce.

Dr. Herderick shares insights on the integration of creative and engineering disciplines, the need for hands-on experience, and the role of the investment community in driving the industry's growth. The conversation also touches on the significance of industry partnerships in reshaping education, making additive manufacturing more accessible, and preparing the next generation of skilled professionals.

01:33 The Evolution of Additive Manufacturing

02:12 Integration of Art and Engineering

05:00 Specialization in Additive Manufacturing

08:44 Industry Trends and Workforce Development

15:25 Additive Manufacturing in Education

39:50 Hands-On Experience and T-Shaped Expertise

50:55 Investment and Market Segmentation

Policy, Innovation & Defense Additive Manufacturing: A Deep Dive with America Makes - Part 1 Dec 16, 2025

Show notes

In this episode of the Additive Snack Podcast, host Fabian Alefeld is joined by Kimberly Gibson from America Makes for the first part of a two-part series focusing on the advancements and policy drivers in additive manufacturing in the U.S. Kimberly dives into the history and mission of America Makes, provides insights on policy innovation, industrial resilience, and how these factors are converging to reshape U.S. and global manufacturing landscapes.

Highlighting the critical roles of workforce development, digital manufacturing, and ecosystem integration, Kimberly also discusses the importance of diversifying the industrial base's focus beyond defense and shares updates on current legislative initiatives like the National Defense Authorization Act. Don't miss this in-depth discussion on the transformative potential of additive manufacturing.

00:30 Meet Kimberly Gibson and Ed Herrick from America Makes

01:26 Kimberly's Journey and the Evolution of America Makes

03:35 The Role of America Makes in US Manufacturing

06:28 Challenges and Opportunities in Additive Manufacturing

11:49 The Importance of Digital Manufacturing and Cybersecurity

19:22 Government's Role in Accelerating Additive Manufacturing

25:07 Diversifying Beyond Defense Contracts

28:54 Congress Signals Support for Advanced Manufacturing

29:33 Senate Bill 2214 and the Additive Industry

31:44 Challenges in the Additive Manufacturing Sector

33:41 Right to Repair and Sustainment Issues

35:53 Unprecedented Demand for Additive Manufacturing

37:54 Additive Manufacturing in Various Sectors

43:39 Energy Sector and Additive Manufacturing

46:32 Additive Construction and Future Prospects

49:14 Teaming and Collaboration Opportunities

50:23 Final Thoughts and Future Outlook

AM in Turbomachinery: Deep dive in Applications, Materials, Production & Qualification Dec 09, 2025

Show notes

In this episode of the Additive Snack Podcast, host Fabian Alefeld delves into the technically demanding world of gas turbines with Dr. Ilya Fedorov, an R&D project manager at Siemens Energy. The discussion covers the transformative impact of additive manufacturing on turbo machinery, touching on innovations in combustion systems, turbine blades, and repair processes.

Dr. Fedorov explains how Siemens Energy harnesses additive manufacturing to improve performance, strengthen supply chains, and embrace green fuels like hydrogen. The episode also explores the rigorous qualification processes for additive components, the development of new materials, and the potential future advancements in the sector.

Long-Term Lifetime Validation of Hot Turbine Guide Vanes Manufactured by Laser Powder Bed Fusion | J. Eng. Gas Turbines Power | ASME Digital Collection

00:00 Introduction to Additive Manufacturing in Gas Turbines

01:47 Ilya Fedorov's Journey into Additive Manufacturing

05:00 The Light Bulb Moment: Realizing Additive's Potential

09:49 Siemens Energy's Additive Manufacturing Strategy

15:03 Challenges and Innovations in Gas Turbine Environments

19:25 Additive Manufacturing Applications in Gas Turbines

25:11 Repair and Longevity of Gas Turbine Components

36:52 Qualification and Testing of Additive Components

44:57 Materials and Process Development in Additive Manufacturing

49:39 Future Directions and Challenges in Additive Manufacturing

59:05 Conclusion and Final Thoughts

Breaking - Euler Launch: AI & the Future of AM Monitoring Nov 14, 2025

Show notes

In this episode of the Additive Snack Podcast, host Fabian Alefeld welcomes Eythor Eiriksson, founder and CEO of euler, a company revolutionizing process monitoring and quality assurance in additive manufacturing. They delve into how euler leverages AI and data from existing sensors to improve print outcomes without requiring additional hardware. Eiriksson shares his journey from Iceland to founding euler, the company's objectives, and their strategies for problem-solving in the additive manufacturing space.

The discussion also touches on the practical applications of AI, user experiences, and the future of additive manufacturing technology. Eiriksson talks about euler’s upcoming product launch at Formnext and its potential to transform the industry by providing real-time monitoring and predictive alerts, ultimately aiming to ensure high-quality prints and reduce costly failures.

00:00 Welcome to Additive Snack Podcast

00:10 Guest Introduction: Eythor Eiriksson and euler

01:21 Eythor's Journey and Background

03:03 Challenges in Additive Manufacturing

04:43 Founding of euler and Initial Steps

05:41 Comparison with Tesla's Autonomous Strategy

07:22 euler's Mission and Vision

09:35 Product Launch and User Experience

15:00 Technical Insights and Failure Detection

28:59 Future of AI in Additive Manufacturing

42:24 Closing Remarks

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