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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:

Personalized Spinal Bracing Made Reality with Additive Manufacturing Apr 23, 2024

Show notes

Additive manufacturing (AM) isn't just shaping the future of medical devices, it is actively changing lives. As it opens new possibilities for patient care around the globe, innovative 3D design solutions are raising the bar for patient comfort and satisfaction.

Today, Host Fabian Alefeld speaks with Lisa Tweardy, CEO of MIGN, a company leading the charge in innovative spinal brace technology that leverages industrial 3D printing. We have Dr. Baron Lonner, a leader in minimally invasive scoliosis surgery, Isabelle (Liz) Rauch, Orthotist for Dr. Lonner of Orthotic Consultants, and Livi Lasner, founder of Save a Spine, an organization she started to connect those who need spinal braces with the financial support to obtain them. Together they explore how additive manufacturing is revolutionizing not only healthcare but spinal health from a personal and technological perspective.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key takeaways:

[1:48] A patient's physical and psychological comfort are essential components of spinal brace design.

[9:36] MIGN is the first and only company to personalize orthopedic bracing at scale.

[15:13] How additive technology allows Dr. Lonner to approach scoliosis treatment differently.

[19:31] An end-to-end digital design workflow allows MIGN to send production requirements anywhere in the world.

[22:12] The mission of the Save a Spine organization.

Resource links:

Dr. Baron Lonner

Fatigue & Fracture Behavior in AM Materials with Nima Shamsaei of Auburn University Apr 16, 2024

Show notes

The ultimate goal for additive manufacturing (AM) is for those creating, building, and designing for our future to reach for AM as another tool in their toolbox as easily as they would a traditional manufacturing method. To build this trust and knowledge of industrial 3D printing, countless hours of research are necessary.

To learn more about the research being performed at Auburn University that is shaping the future of AM, Host Fabian Alefeld speaks with a distinguished AM figure, Nima Shamsaei. Nima is a Philpott-West Point Stevens professor at Auburn University and Director of the National Center for Additive Manufacturing Excellence (NCAME). At NCAME, Nima and his team are at the forefront of research and technology and are actively studying the fracture and fatigue behavior of AM materials. In addition, a joint project with the US government and Auburn University is supporting manufacturers to create components for NASA.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:39] An interest in mechanical properties led Nima from automotive to pushing the AM envelope with NASA.

[6:33] How Nima detects the fatigue behavior of additive materials.

[9:31] Three challenges of collecting and leveraging additive material data.

[16:19] When cost is not an issue, leveraging additive design maximizes its full potential.

[19:48] Part classifications are based on qualification complexities and the consequence of failure.

[23:21] A joint effort by the US government, Auburn University, and NASA support manufacturers to create parts NASA can use.

A.I. in Additive Manufacturing with Omar Fergani of 1000 Kelvin Apr 09, 2024

Show notes

It's clear that AI and additive manufacturing (AM) are a natural marriage of innovative technologies. As more companies focus on solutions that fortify the supply chain and increase the speed of engineering ingenuity, AM adoption will continue to accelerate.

Today, host Fabian Alefeld speaks with the co-founder and CEO of 1000 Kelvin, Omar Fergani. 1000 Kelvin is a company at the forefront of the AI-driven revolution in the AM industry. Omar explains the depths of the innovation driven by 1000 Kelvin, the pivotal role that AI plays in industrial 3D printing, and how the AMAIZE co-pilot helps engineers to reduce design time and engineer onboarding.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key takeaways:

[1:18] 1000 Kelvin’s mission and how it plans to solve additive manufacturing’s biggest challenges.

[6:26] How implementing a materials processing discipline will move additive manufacturing to serial production.

[10:41] 1000 Kelvin’s AMAIZE is a co-pilot engineering tool and thermal management platform.

[12:58] On a macro level, AMAIZE helps to onboard new engineers.

[19:45] How the co-pilot integrates into the design workflow.

[22:09] Business use cases support the growth of AM spare parts and fortify the supply chain.

[26:03] The limitations and advantages of AI in AM.

A Space Roundtable with NASA, Rocket Lab, The European Space Agency, and TRUMPF Apr 02, 2024

Show notes

Space exploration and additive manufacturing (AM) are accelerating rapidly. SpaceX was able to reach orbital velocity with its latest starship launch, providing beautiful imagery upon its reentry. Rocket Lab had its 45th launch, with 22 additional launches planned for this year, and the first metal 3D printer installation on the International Space Station (ISS). With these accomplishments achieved, where will AM fit into our space journey's future?

To find out, Host Fabian Alefeld ventures into the final frontier with a space roundtable with an all-star panel, featuring Paul Gradl, Principal Engineer at NASA, Myles Keefer, Manager of Additive Manufacturing at Rocket Lab, Eliana Fu, Industry Manager of Aerospace & Medical at TRUMPF, and Advenit Makaya, Advanced Manufacturing Engineer at the European Space Research and Technology Centre of the European Space Agency.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key takeaways:

[2:28] Additive manufacturing is a critical component of space exploration.

[5:50] Common additive manufacturing challenges in space applications.

[10:57] Additive manufacturing adoption in Europe.

[13:28] Challenges of materials development today, and in the future.

[26:16] How to leverage additive manufacturing for new innovative projects.

[40:30] Machine manufacturer pain points and challenges.

[51:48] What is driving additive innovation in Europe?

[1:00:17] How to inspire a new generation of manufacturing engineers.

Resource links:

European Space Agency

3D Printing Offers Opportunity to Custom Bike Designers with Kris Henry of 44 Bikes Mar 26, 2024

Show notes

Bike enthusiasts understand the importance of quality welds, dynamic suspensions, and low-maintenance bikes. But to have a bike custom designed to their unique specifications is a dream come true. Today’s guest not only builds custom bikes he designs the parts using additive manufacturing (AM).

Today, host Fabian Alefeld speaks with the owner and founder of 44 Bikes, Kris Henry, and EOS’ Spencer Thompson. Kris shares his passion for creating custom bikes and describes how he uses the design and supply chain aspects of AM to make handcrafted custom bikes accessible to a larger user group. Spencer offers insights into the state of AM adoption by small business owners, highlights the partnership opportunities available to manufacturers, and shares the hurdles independent builders face in the AM space.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[2:11] 44 Bikes was born of Kris’ love of bicycles and his passion for designing things.

[8:48] The benefits of additive manufacturing in building custom bicycles.

[20:07] 3D printing offers small shop owners and bike enthusiasts a whole new level of design.

[26:29] Supply chain challenges and speed to market increase AM adoption in small businesses.

[34:22] When only a few parts are needed, finding manufacturers to partner with is a big hurdle.

[36:03] The lack of protocols or universal standards for additive manufacturing creates a huge learning curve for independent builders.

Resource Links:

Spencer Thompson on LinkedIn

The History of Additive Manufacturing in the U.S. Army with L.J. Holmes Mar 19, 2024

Show notes

Are you curious about how the U.S. Department of Defense (DoD) uses additive manufacturing (AM)? The military’s innovative approach has a 30-year roadmap, which was authored by this week’s guest.

In this special episode, host Fabian Alefeld speaks with LJ Holmes. LJ has one of the most diverse jobs in the AM industry. He is the Executive Director of Advanced Manufacturing Research and Engineering at Harrisburg University. His rich background in AM from its historical roots in the DoD to current uses and future applications. LJ describes his AM journey from the Army Research Center to Harrisburg University, how AM has evolved within the defense sector, and some undocumented stories of early use cases and current applications within the DoD.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:50] LJ shares his journey to AM and the integration of AM at the Army Research Center and the Department of Defense.

[11:47] Authoring the 30-year Additive Manufacturing Roadmap was the last project LJ completed for the Army Research Center.

[17:15] Harrisburg University of Science and Technology offers students an advanced manufacturing curriculum and STEM-focused education.

[26:35] Additively manufactured components may or may not have been used in military vehicles as early as the 2000s.

[29:41] Additive applications for future civilian and military use.

[42:17] During AMUG 2024, LJ will introduce a 50-foot-tall friction stir hybrid additive machine.

Resource Link:

LJ Holmes on LinkedIn

Harrisburg University of Science and Technology

ASTROA.org — AM Forward focus

Building Dumb Parts is a Smart Concept with Pieter Ruijssenaars Mar 12, 2024

Show notes

The expenses associated with capital investments, storing inventory, and dealing with supply chain delays pose significant challenges for companies that keep a large stock of parts. However, if these companies were able to produce the required parts whenever they are needed, without the need for maintaining costly inventories, the advantages of adopting additive manufacturing (AM) becomes evident.

In this episode, host Fabian Alefeld speaks with Pieter Ruijssenaars, the CEO and founder of DiManEx. DiManEx is redefining the AM supply chain network for its clients. Pieter describes how AM navigates the complexities of supply chains, making them more resilient, especially in the light of current geo-political tensions, his smart concept of printing 'dumb parts', and how DiManEx builds digital inventories that lead to sustainable and cost-effective business strategies.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[3:00] Pieter’s view on how AM can help build more resilient supply chains.

[7:29] The printing of ‘dumb parts’ that solve real problems is a smart concept.

[12:17] How DiManEx illustrates the business case for additive within an organization.

[22:00] DiManEx utilizes the R-ladder concept to validate the sustainability of additive manufacturing with clients.

[32:33] The future of AM adoption from Pieter’s perspective.

Creating the Future of Energy with Dr. Alaa Elwany Mar 05, 2024

Show notes

The US has always been a hotbed of innovation. With the integration of additive manufacturing (AM), AI, and advancements in materials and manufacturing technologies, creating clean, abundant energy is within reach. This conversation highlights the role of AM in next-generation energy technology.

Host Fabian Alefeld speaks with Dr. Alaa Elwany, science and technology policy fellow at the U.S. Department of Energy, Advanced Manufacturing Office. Alaa is a recognized expert in additive manufacturing and a key advisor in the realm of science and technology to the U.S. government. He is currently serving as a science and technology fellow at the US Department of Energy and as a professor at Texas A&M at the Department of Industrial and System Engineering. Fabian and Alaa talk about Alaa's experience within the DOE, the intersection of AM and energy, the future of smart manufacturing and digital manufacturing, and resources for business owners looking to expand their AM opportunities.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:24] Alaa explains his role within the DOE and how he and his team are shaping the future of energy.

[3:36] Additive manufacturing is versatile and scalable enough to be used in major clean energy projects.

[8:18] Materials that have a high relevance to energy applications.

[11:38] Additive’s foundational role in increasing supply chain resilience.

[16:48] Next-gen energy technology includes additive manufacturing.

[20:48] The future of integrating smart manufacturing and AI into additive manufacturing.

[30:33] The vital role of government investment, regulation, and support for the future of additive and smart manufacturing.

A Dynamic Panel Discussion with the Digital Foam Architects Network Feb 20, 2024

Show notes

The innovative and intricate world of Digital Foam is an evolution of polymer lattice structures. In the past, developing applications for polymer lattice structures, especially for performance applications, has been challenging. Challenges include aspects of design, printing, post-processing, and materials. All the value chain elements influence each other, adding more complexities.

In this special episode, Host Fabian Alefeld speaks with four panelists from the Digital Foam Architects Network about the full process chain and the complexities and opportunities of Digital Foam. Joining the panel discussion are Pierre Gonnetan, business development manager at Arkema, Mike Schorr, general manager at DyeMansion, Nick Florek, CEO of General Lattice, and Dr. Dave Krzeminski, senior Additive Minds consultant at EOS. The goal of the Digital Foam Architects Network is to increase accessibility, scalability, and speed up development for performance-based lattice structures.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key takeaways:

[3:08] The history of polymer lattice structures and methodologies of production with Nick Florek

[7:54] Dave Krzeminski on overcoming the challenges of an ever-changing technology

[15:00] Objectives and initiatives of the Digital Foam Architects Network

[19:41] Pierre Gonnetan on the material landscape and key drivers for digital foam applications

[31:03] Mike Schorr on the importance of post-processing aspects of Digital Foam.

[38:41] Mike Schorr explains the complex process of creating uniformity in powdering, coloring, and smoothing polymers.

[48:48] Nick Florek unpacks the coordination and parameters of the digital design phase.

[56:23] Additional industrial opportunities for Digital Foam applications.

Resource Link:

General Lattice

The Biggest Influencer in 3D Printing - Joel Telling, The 3D Printing Nerd Feb 13, 2024

Show notes

Consumer 3D printing and industrial additive manufacturing (AM) are more closely related than many in the industry realize. Supply chain considerations, material development, and the ever-growing need for a robust workforce are valid concerns for both movements.

In this episode, Host Fabian Alefeld speaks with YouTube influencer and content creator Joel Telling, the 3D Printing Nerd. Together, they dive into the fascinating interface between consumer and industrial 3D printing. Joel transitioned from software development to becoming a leading voice in the 3D printing industry with more than 600k subscribers to his 3D Printing Nerd YouTube channel. Joel is a key voice in the industry, an additive expert himself, and a friendly face to EOS in the 3D printing industry.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key takeaways:

[1:56] The adoption of additive manufacturing in various industries has a lot to do with public perception.

[8:55] Joel describes the challenge of integrating additive’s industrial applications with consumer products and applications.

[17:15] How Joel transitioned from software engineer to the AM influencer, The 3D Printing Nerd.

[21:23] How software engineering works within the additive manufacturing framework.

[25:15] Why understanding the industrial and consumer side of AM is beneficial for the entire industry.

[29:53] Joel’s recommendations for consumer machines and materials for newbies wanting to experiment with 3D printing projects.

[40:16] Joel’s advice for those interested in 3D printing, find a community of like-minded people, and meet up.

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