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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:

How to Accelerate and Mature Manufacturing with Barry Hulce of VTMC Feb 06, 2024

Show notes

Picture a future where values and supply chains are robust and agile. The workforce is skilled in high-tech disciplines such as additive manufacturing (AM). And the manufacturing industry has taken back its important role, not only within the US but all around the world. This vision is currently being modeled in Vermont.

Joining Host Fabian Alefeld is Barry Hulce, the Executive Director of Vermont’s Manufacturing Collaborative (VTMC). In this episode, Barry unpacks the complexities of modern manufacturing, dives into the challenges of workforce development, and reveals how his organization is constructing a robust manufacturing infrastructure that is set to accelerate the adoption of additive manufacturing.

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:

[1:21] Industry agnostic, Barry enjoys working with systems that help people.

[8:20] The purpose and intention of Vermont Manufacturing Collaborative.

[12:09] How VTMC’s ecosystem will be duplicated and scaled for rural communities.

[17:35] VTMC’s plan for increasing capacity and developing the future AM workforce.

[23:31] How educating an AM workforce differs from conventional manufacturing technologies.

[34:05] VTMC’s technological capabilities and the development stages of active products.

Advancements in Monitoring, Beam Shaping, and Cutting-Edge AM Research from The Ohio State University Jan 30, 2024

Show notes

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 additive.snack@eos-na.com. 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.

Life-Changing Reconstructive Surgeries Made Possible by Metal 3D Printing -- The Princess Moshoana Story Jan 23, 2024

Show notes

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 additive.snack@eos-na.com. 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

Additive Evolution: Navigating Orthopedics and the Shift in Manufacturing with Derek VanDenDriessche Oct 17, 2023

Show notes

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 additive.snack@eos-na.com. 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?

The Future of Medicine: A Conversation about AM in Healthcare with Mark Morrison, Smith & Nephew Oct 10, 2023

Show notes

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 additive.snack@eos-na.com. 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?

Evolving the Orthopedic Frontier: A Deep Dive into the History of Medical AM with Charles Hansford Sep 26, 2023

Show notes

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 additive.snack@eos-na.com. 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.

Revolutionizing Healthcare: The Future of Customized Medical Manufacturing with Cambre Kelly Sep 19, 2023

Show notes

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 additive.snack@eos-na.com. 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.

Unlocking the Potential: 3D Printing’s Impact on Medical Innovation and Beyond with Laura Gilmour Sep 12, 2023

Show notes

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 additive.snack@eos-na.com. 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.

Building the Future: The Journey of The LEGO Group in AM Sep 05, 2023

Show notes

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 additive.snack@eos-na.com. 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?

Step into the Future: Doc Sols’ 3D Printed Revolution in Podiatry Aug 29, 2023

Show notes

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 additive.snack@eos-na.com. 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?

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