3Degrees Discussions

Metal Additive Manufacturing: From Contract Manufacturing to Defense Applications | Matthew Carl

What does it take to move metal additive manufacturing from prototyping to reliable production? How are companies using laser powder bed fusion (LPBF) to manufacture complex components for aerospace, oil and gas, and defense applications?

In this episode of 3Degrees Discussions, host Dr. Mike Vasquez speaks with Matthew Carl, Mission Team Design Engineer at HUXWRX Safety Co. and former Manufacturing Engineer at Knust-Godwin, about his career in metal 3D printing and the practical challenges of industrial additive manufacturing.

Matthew spent more than a decade at Knust-Godwin, a precision contract manufacturer serving the energy, aerospace, and defense industries. His experience includes laser powder bed fusion, manufacturing engineering, process control, and managing complex production requirements. He now brings that experience to HUXWRX Safety Co., a manufacturer specializing in advanced suppressor technologies.

TOPICS COVERED

• Metal Additive Manufacturing (LPBF): Real-world applications of laser powder bed fusion and the challenges of manufacturing complex metal components.

• Contract Manufacturing: Lessons from more than 10 years at Knust-Godwin, supporting demanding industrial customers and applications.

• Scaling Additive Manufacturing: Moving beyond prototypes toward repeatable production, including process development, quality control, and manufacturing consistency.

• Defense and Aerospace Manufacturing: The role of additive manufacturing in producing specialized components with challenging performance requirements.

• Design for Additive Manufacturing (DfAM): Balancing design freedom, material properties, manufacturing constraints, and production economics.

• The Future of Metal 3D Printing: Opportunities and challenges as additive manufacturing technologies mature and see broader industrial adoption.

This conversation offers perspectives for manufacturing engineers, materials scientists, additive manufacturing professionals, and organizations evaluating metal 3D printing for industrial production.

ABOUT MATTHEW CARL

Matthew Carl is a Mission Team Design Engineer at HUXWRX Safety Co. Previously, he spent over 10 years as a Manufacturing Engineer at Knust-Godwin, specializing in laser powder bed fusion and precision manufacturing.

HUXWRX Safety Co.: https://huxwrx.com

Knust-Godwin: https://www.kgsbo.com

ABOUT 3DEGREES DISCUSSIONS

Hosted by Dr. Mike Vasquez, 3Degrees Discussions features conversations with the engineers, entrepreneurs, researchers, and industry leaders advancing additive manufacturing and 3D printing technologies.

Dr. Vasquez is the Founder & CEO of 3Degrees and holds a PhD in Additive Manufacturing from Loughborough University and BS/MEng degrees in Materials Science and Engineering from MIT.

LEARN MORE

3Degrees | Additive Manufacturing Engineering, Materials Science & Qualification

https://www.3degreescompany.com

TRACEAM | Additive Manufacturing Data Management, Quality Analytics & Managed Data Services

https://www.traceam.com

VEC | Advanced Manufacturing Strategy & Advisory

https://www.vecstrategy.com

Subscribe to 3Degrees Discussions for more conversations about metal 3D printing, additive manufacturing technology, materials science, manufacturing innovation, and industrial production.

#AdditiveManufacturing #Metal3DPrinting #LPBF #AdvancedManufacturing #3DegreesDiscussions

Derek Hass | Materials Science, Innovation & the Future of Advanced Manufacturing | 3Degrees Discussions

In this episode of 3Degrees Discussions, host Mike Vasquez sits down with Derek Hass of the Commonwealth Center for Advanced Manufacturing (CCAM) to explore the intersection of materials science, advanced manufacturing, and industrial innovation.

Drawing on more than 25 years of experience, Derek shares his perspective on translating research into practical manufacturing solutions, the importance of collaboration between industry, academia, and government, and the challenges of bringing emerging technologies into production.

In this conversation, we explore:

Derek's career in materials science and advanced manufacturing

Bridging the gap between research and industrial applications

The role of CCAM in accelerating manufacturing innovation

Collaboration across industry, academia, and government

Emerging opportunities in additive and advanced manufacturing

Connect with Derek and CCAM:

Derek Hass on LinkedIn: https://www.linkedin.com/in/derek-hass-a9ba0716/

Commonwealth Center for Advanced Manufacturing (CCAM): https://www.ccam-va.com/

About 3Degrees Discussions

3Degrees Discussions features conversations with the innovators, entrepreneurs, and industry leaders shaping the future of additive manufacturing.

Learn more about our work:

3Degrees | Materials science, engineering, and additive manufacturing consulting

https://www.3degreescompany.com/

TRACEAM | Manufacturing data management, quality analytics, and managed data services

https://traceam.com/

VEC | Advanced manufacturing strategy, advisory, and workforce development

https://vecstrategy.com/

Subscribe for more conversations on additive manufacturing, materials science, and the technologies transforming modern manufacturing.

#AdditiveManufacturing #AdvancedManufacturing #MaterialsScience #ManufacturingInnovation #3DPrinting

In this episode of 3Degrees Discussions, Mike Vasquez sits down with Justin Levy, founder of DefendAM, to discuss one of the most important challenges facing the U.S. defense industrial base: building secure, scalable, domestic manufacturing capacity for unmanned aerial systems.

Justin shares his journey into additive manufacturing and defense, his experience supporting Air Force and Navy manufacturing programs, and why he founded DefendAM to strengthen America's ability to rapidly produce mission-critical drone systems. The conversation explores the intersection of additive manufacturing, defense production, supply chain resilience, and the future of domestic manufacturing.

Topics discussed include:

The current state of U.S. drone manufacturing

Building resilient domestic supply chains

Additive manufacturing's role in defense production

Lessons learned from working with Air Force and Navy programs

SBIR/STTR innovation and technology transition

The future of the defense industrial base

Whether you're involved in additive manufacturing, aerospace, defense, or advanced manufacturing, this episode offers valuable insight into the opportunities and challenges shaping the next generation of American manufacturing.

Learn more about 3Degrees and TRACEAM: https://www.3degreescompany.com

Subscribe for more conversations with leaders across additive manufacturing, materials, and the defense industrial base.

#AdditiveManufacturing #3DPrinting #Defense #DroneTechnology #UAS #DefenseIndustrialBase #AdvancedManufacturing #Manufacturing #Aerospace #SBIR #TRACEAM

In this episode of 3Degrees Discussions, host Mike Vasquez sits down with Jon Walker, a manufacturing industry veteran with more than two decades of experience spanning machining, automation, additive manufacturing, and Industry 4.0.

Throughout his career, Jon has held leadership positions with Mazak, GF Machining Solutions, EOS, and Xometry, helping manufacturers evaluate, adopt, and scale advanced manufacturing technologies. His experience provides a unique perspective on how traditional manufacturing and emerging technologies are converging to shape the future of the industry.

During the conversation, Jon shares insights from his journey through manufacturing sales and business development, lessons learned from working with companies across aerospace, automotive, and industrial markets, and his perspective on the opportunities and challenges facing manufacturers today. We also discuss additive manufacturing adoption, digital transformation, automation, workforce development, and where Industry 4.0 is delivering real value.

Whether you're involved in additive manufacturing, machining, automation, or manufacturing leadership, this episode offers practical insights from someone who has spent his career helping organizations navigate technological change.

Topics discussed:

Jon's manufacturing career journey

Additive manufacturing adoption and growth

Industry 4.0 and digital transformation

Automation and advanced manufacturing technologies

Sales and business development in manufacturing

Workforce development and industry trends

Opportunities and challenges facing manufacturers

Learn more about 3Degrees: www.3degreescompany.com

#AdditiveManufacturing #AdvancedManufacturing #Industry40 #Manufacturing #3DPrinting #DigitalManufacturing #Automation #EOS #Xometry #Mazak #ManufacturingLeadership #3DegreesDiscussions

In this episode of 3Degrees Discussions, Mike Vasquez sits down with David Helmers, owner of Wolfpack Workshop, a startup additive manufacturing and engineering company based in Columbus, Ohio.

David shares his journey as a mechanical engineer and entrepreneur, drawing on hands-on experience in CNC machining, 3D printing, sheet metal fabrication, welding, and design for manufacturing. The conversation explores what it takes to build a business in the additive manufacturing space, lessons learned from practical engineering work, and where David sees opportunities for the next generation of manufacturing innovation.

Topics discussed include:

• Starting and growing an additive manufacturing business

• Practical applications of 3D printing in engineering and production

• Design for manufacturing and the role of craftsmanship

• Entrepreneurship in manufacturing

• Opportunities and challenges in the future of additive manufacturing

If you enjoy conversations with innovators, entrepreneurs, and leaders in 3D printing, be sure to like, subscribe, and follow 3Degrees Discussions.

Learn more at www.3degreescompany.com

For additive manufacturing support, materials qualification, or consulting inquiries: [email protected]

Listen to 3Degrees Discussions on Spotify, Apple Podcasts, Amazon, and Stitcher.

#AdditiveManufacturing #3DPrinting #Engineering #Manufacturing #CNCMachining #DesignForManufacturing #Entrepreneurship #MechanicalEngineering #AM #3DegreesDiscussions

From South Bend, Indiana, welcome to 3Degrees Discussions — I’m your host, Mike Vasquez.

This podcast dives into the stories behind the innovators, entrepreneurs, and leaders shaping the 3D printing industry.

In this episode, I’m joined by Bryan Sherman, Chief Metallurgist at DSH Technologies. Bryan brings over two decades of experience in metal injection molding (MIM) and sinter-based manufacturing, with deep expertise in debinding, sintering, and process development across both MIM and metal additive manufacturing.

His background spans part design through full-scale production, giving him a unique perspective on process control, repeatability, and quality. As interest continues to grow in sinter-based additive manufacturing, Bryan shares lessons learned from MIM and how they apply to scaling AM technologies today.

Learn more & subscribe:

Visit www.3degreescompany.com

Listen on your favorite platform:

Available on Spotify, Apple Podcasts, Amazon Music, and more

Work with us:

Looking for support with materials, qualification, or additive manufacturing strategy?

Reach out at [email protected]

From South Bend, Indiana — welcome to 3Degrees Discussions, hosted by Mike Vasquez.

This podcast explores the stories behind the innovators, entrepreneurs, and technical leaders shaping the world of additive manufacturing and advanced production.

In this episode, Mike sits down with Steven Floyd, an experienced engineering and technology leader focused on accelerating the adoption of additive and advanced manufacturing. Steven is the CEO and Chief Engineer of Floyd Technology Consulting LLC, where he works with organizations to implement cutting-edge manufacturing technologies and drive innovation strategies.

Prior to launching his consulting firm, Steven led additive manufacturing technology development at Northrop Grumman, guiding multidisciplinary teams across aerospace and defense applications. His experience spans polymer, composite, ceramic, and metal AM technologies, as well as strategic engineering partnerships and R&D initiatives.

Tune in as we discuss leadership in advanced manufacturing, scaling innovation inside large organizations, and what it really takes to move additive from development to deployment.

Subscribe to 3Degrees Discussions wherever you listen to podcasts — including Spotify, Apple Podcasts, Amazon Music, and more.

For more episodes and resources, visit:

👉 www.3degreescompany.com

If your organization is looking for support in materials, qualification, or additive manufacturing strategy, reach out to the 3Degrees team at [email protected]

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From South Bend, welcome to 3Degrees Discussions. I’m your host, Mike Vasquez, and this podcast explores the stories behind the innovators, entrepreneurs, and leaders shaping the world of additive manufacturing and 3D printing.

In this episode, I’m joined by Daniel Werner, a materials engineer specializing in powder bed fusion across both polymer and metal additive manufacturing. Daniel previously worked at EMS, supporting materials development and customer-facing AM programs, and is currently focused on advancing PBF materials and accelerating their transition from R&D into scalable, production-ready applications with INSPIRE in Switzerland.

During our conversation, Daniel offers a candid perspective on the realities of materials commercialization in additive manufacturing, noting that “it typically takes four years and more than two million dollars to transition a new powder concept from early development to full commercial deployment.” We dig into what drives that timeline and cost, where companies tend to underestimate the effort, and how teams can better position new materials for successful scale-up.

Before we get started, head over to 3Degrees at www.3degreescompany.com

and subscribe to the podcast. You can listen to 3Degrees Discussions wherever you get your podcasts, including Spotify, Apple Podcasts, Amazon Music, and Stitcher.

If you or your organization are looking for support with materials development, qualification, or broader additive manufacturing strategy, reach out to the 3Degrees team through our website or by email at [email protected]

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For more episodes, insights, and AM content, visit www.3degreescompany.com

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From South Bend, Indiana, welcome to 3Degrees Discussions. In this episode, Mike sits down with Haden Quinlan, Senior Program Manager at MIT’s Center for Advanced Production Technologies (ADAPT). Haden has been a key force across MIT’s innovation ecosystem—supporting startups, building industry partnerships, and shaping how additive manufacturing and digital production move from research into real-world deployment.

We explore his path through MIT, the evolving landscape of AM workforce development, and how universities, industry, and government can better collaborate to accelerate adoption and impact.

Connect with Haden on LinkedIn:

https://www.linkedin.com/in/hquinlan/

Before we get started, head over to www.3degreescompany.com

to subscribe. You can listen to the show on Spotify, Apple, Amazon, Stitcher, or wherever you get your podcasts. And if your team needs support with materials, qualification, or AM data and workflow management, reach out at [email protected]

.

Be sure to visit www.3degreescompany.com

for more content and episodes.

From South Bend, Indiana, welcome to 3Degrees Discussions — the podcast devoted to the stories behind the innovators, entrepreneurs, and leaders in the 3D printing and advanced manufacturing world. I’m your host, Mike Vasquez.

In this episode, I’m joined by Jonathan Pegues. Jonathan helps teams push the science and application of advanced manufacturing forward, with a career rooted in:

Microstructural analysis

Process and build optimization

Practical problem-solving across refractory and reactive alloy systems

Jonathan has a rare ability to translate deep technical insights into real-world manufacturing solutions—improving product performance, streamlining development cycles, and bridging the gap between R&D, manufacturing operations, and industry partners. Throughout his career, he’s focused on helping organizations understand how manufacturing decisions impact material behavior, structural performance, and long-term reliability.

🔗 Connect with Jonathan on LinkedIn:

https://www.linkedin.com/in/jonathan-pegues/

Before we get started, head over to www.3degreescompany.com

and subscribe to the podcast.

You can listen to 3Degrees Discussions wherever you get your podcasts, including Spotify, Apple, Amazon, and Stitcher.

If you or your company are looking for materials, qualification, or general Additive Manufacturing support, reach out to the 3Degrees team:

🌐 Website: https://www.3degreescompany.com

📧 Email: [email protected]

Thanks for listening, and enjoy the conversation with Jonathan Pegues.