Mark Barfoot is a 3D printing veteran who began by introducing additive manufacturing to traditional firms before becoming Managing Director of the Multi-Scale Additive Manufacturing Lab at the University of Waterloo. He later worked for Cimetrix and Javelin, two major 3D printing resellers, before spending a stint at EWI. Now, he serves as VP of Engineering at Voxel Innovations, an electrochemical polishing and machining firm capable of remarkable advancements. In this episode of the 3DPOD, we explore finishing techniques, the future of 3D printing resellers, and much more.

Joe Calmese talks to us about the financing of additive manufacturing, machine prices, and utilization. He runs ADDMAN, a large, high-end service bureau that produces many critical components, including defense articles. Naturally, in this episode of the 3DPOD, we discuss defense, as well as niobium and its applications. Joe’s enthusiasm and deep understanding of the subject are infectious, taking you on a journey toward greater efficiency in manufacturing. The manufacturing opportunity is substantial, and Joe shares how he plans to tackle it, ensuring ADDMAN grows while staying true to its core values.

Adam Travis, Global AM Program Leader at Westinghouse, is lifting the veil of secrecy surrounding 3D printing in the nuclear industry for us in this episode of the 3DPOD. He delves into the qualification process for nuclear power components, examines material selection, and explores designing for longevity spanning decades. We discuss the nuclear sector’s approach to its supply chain and the parts being manufactured for the industry. Adam also shares an exciting story about how Westinghouse leveraged 3D printing to maintain power in Ukraine. Additionally, we have a compelling conversation about aluminum and its rise as a prominent material in additive.

Adam Travis will be participating on Panel 4: Applications at Additive Manufacturing Strategies, taking place in New York City February 4 – 6, 2025.

In this episode of the 3DPOD, we take a deep dive into 3D printing for golf. Cobra PUMA Golf has gone further than other firms, employing Multi Jet Fusion, binder jet, and powder bed fusion for production golf clubs. Better putters and metal drivers are now achievable through 3D printing. But how did Ryan Roach, Cobra Golf’s Director of Innovation, and his team make this possible? What challenges did they face? And is 3D printing a passing trend in golf or a fundamental evolution? Our producer Jake explores some golf-specific questions, leaving us convinced that the union of golf and 3D printing represents a transformative development for both.

Roach will also be speaking at Additive Manufacturing Strategies on Feb. 4, 2025 in New York City to discuss in more detail about Cobra Golf’s journey to expand use of additive manufacturing into its product line.

Nick Sonnentag is a Senior Principal Engineer at Oshkosh, where he contributes to the development of some of the world’s toughest vehicles using additive manufacturing (AM). Drawing on experience from ATI, DuPont, and more, Nick possesses broad and deep expertise in 3D printing. In this episode of the 3DPOD, we discuss alloys, vehicle manufacturing, applications, and the readiness of directed energy deposition technology for widespread use. Not limiting his exploration of 3D printing to his work at Oshkosh, Nick founded Sunnyday Technologies to tackle the significant challenges in construction 3D printing. Rather than focusing on machines, he concentrates on the binders and the precise formulations needed to achieve specific properties in final structures. This approach stands out for its elegance and promise, diverging from conventional methods of discovering applications and materials. It makes this episode especially insightful.

Nick also wanted to clarify that at one point, he mistakenly referenced General Atomics instead of General Dynamics and asked me to note this for accuracy.

Kevin Ayers spent 30 years at the FBI, contributing to groundbreaking engineering initiatives for the Bureau and beyond. On this episode of the 3DPOD, we’re fortunate to have Kevin sharing some of his once-classified insights on our podcast. It’s fascinating to learn how the FBI utilized 3D printing and just how long they’ve been exploring this technology.

In addition to his FBI tenure, Kevin has been instrumental in 3D printing’s success for nearly two decades, worked at Danfoss, and currently serves as a consultant at 3D Metal Konsulting. His cumulative expertise and perspectives are truly remarkable, making this episode a must-listen.

Andy Davis is Director of Government Solutions at The Barnes Global Advisors. Previously he was at the DOD and the US Army in various logistics, program management, technology advisory roles. In the podcast we discuss austere 3D printing, 3D Printing at the point of need, drones, the military at large and much more. It’s clear that the Navy and Air Force are investing in AM and we delve into the why and what of it. Andy´s views and opinions are steeped in experience and this is a very helpful episode to any coming to grips with military uses for Additive. 

Kate Black is the Chief Executive Officer of Atomik AM, where she leads a team dedicated to fostering innovation and developing integrated advanced manufacturing solutions. The company specializes in electronics 3D printing, jetting technologies for novel materials, coatings, and multi-material 3D printing. Additionally, she serves as a Professor of Manufacturing at the University of Liverpool. In this episode of the 3DPOD, Kate shares her technical vision and a forward-looking perspective that will captivate many. She also emphasizes the importance of environmental manufacturing, advocating for cleaner chemistries and technologies.

Melissa Orme played a pivotal role as CTO at Morf3D, transforming the company from a standard service bureau into a leader in aerospace 3D printing that went on to be acquired by Nikon. Now at Boeing, as Vice President of Additive Manufacturing (AM), she spearheads the company’s 3D printing initiatives, aiming to integrate AM wherever practical. Boeing, which has a longstanding lead in low-rate 3D printing production and manufacturing thousands of parts for civilian aircraft, benefits from Melissa’s vision and expertise. In this episode of the 3DPOD, she shares fascinating insights about Boeing’s current advancements and her aspirations for expanding 3D printing’s applications within the company.

Sascha Schwarz is a researcher dedicated to aiding his university, Technical University of Munich (TUM), to foster innovation as CTO of TUM Venture Labs. In this episode of the 3DPOD, we explore diverse startups, the challenges faced by scientists transitioning into entrepreneurial roles, and the incubation of new ventures. Topics include technology transfers, development, and the essential qualities of a successful startup. This conversation is a must-listen for university professionals looking to commercialize technology and for entrepreneurs seeking to gain valuable insights from Sascha’s expertise.