Additive manufacturing (AM) offers unique solutions for complex geometries and high-pressure die-casting efficiency in the automotive industry. As the two industries merge it creates a powerful synergy, elevating both technologies to new heights. 

To explore additive’s impact on the automotive industry, Fabian welcomes Wes Byleveld, Director of Additive Manufacturing at Exco Engineering. For 10 years, Wes has been connecting conventional manufacturing processes with additive innovations. The conversation ranges from eliminating waste, reduction of porosity, cycle-time reduction, and polishing-related downtime. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[1:51] Wes's gap analysis advocated for an additive manufacturing proof of concept. 

[7:57] Integrating high-pressure die-casting and additive manufacturing. 

[19:46] Cost benefits of integrating additive with conventional manufacturing in automotive parts. 

[24:56] Adoption challenges of additive manufacturing in the die-casting industry. 

[32:38] Future innovative technologies that push additive manufacturing forward. 

Resource Links: 

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Wes Byleveld on LinkedIn 

Exco Engineering 

Additive manufacturing (AM) is revolutionizing industries like medicine, aerospace, and defense. To meet these sectors' stringent demands for minimal waste, precise welds, and efficient energy use, innovative solutions are essential. 

To explore the diverse benefits and challenges of laser usage in additive manufacturing, Host Fabian Alefeld welcomes Alex Kingsbury, AM Market Development Manager at nLIGHT Inc. They discuss cutting-edge advancements in laser technology, productivity gains realized with beam-shaping techniques and the challenges of specializing in innovative beam-shaping laser technologies. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[6:04] Australian AM adoption flourished after early medical-related successes. 

[10:11] Technological opportunities drove Alex’s decision to work at nLIGHT. 

[14:32] How is nLIGHT distinct from other laser manufacturers? 

[17:45] Advantages of laser-powered additively manufactured complex parts. 

[37:50] Challenges of specializing in breakthrough laser technologies. 

[47:57] Innovative future functionality of lasers in additive manufacturing. 

 The current state of additive manufacturing is paradoxical. Its ability to create remarkable objects stands in contrast to the challenges of establishing a compelling business case for its universal use. 

To explore how and when additive will go mainstream, Host Fabian Alefeld welcomes the hosts of the 3DPOD podcast, Joris Peels and Max Bogue. Joris is the executive editor at 3Dprint.com and the VP of Consulting at AM Research. Max Bogue is Chairman and Founder of Wobbleworks and the creator of the innovative 3Doodler, the most popular 3D pen on the market. They discuss the current state of additive, the challenges of implementing AM in organizations, and the sweet spot for growth.  

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[2:18] Frictionless AM experiences help build a use case for other industries. 
 

[13:53] The sweet spot for growth in additive manufacturing. 

[25:05] Saying ‘No’ was the key to the successful execution of Wobbleworks’ 3D pen. 

[40:42] Advice for implementing additive manufacturing within an organization. 

[52:22] Additive must cross the chasm before general adoption. 

[56:20] Blending robotics with AM will drive big growth in the military-industrial complex. 

Resource Links: 

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Follow the Additive Snack Podcast on Youtube 

3DPOD Podcast 

3Doodler 

Joris Peels on LinkedIn 

Max Bogue on LinkedIn 

By adopting space industry best practices, the aviation industry can fully leverage AM to push the design boundaries of aircraft manufacturing. Is widespread adoption the key to realizing the full benefits of this transformative technology? 

To explore how AM impacts the aviation industry, Host Fabian Alefeld welcomes back SpaceX alum and current Head of Manufacturing and Quality at JetZero, Tim Berry, to the podcast. Tim shares his expertise on how JetZero is pioneering the new era of aircraft design, how advancements in the space industry are powering innovations, and how AM can change the aviation industry to make it better. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[1:30] JetZero is creating commercial jets featuring blended-wing bodies and sustainable fuel technology. 

[10:14] Additive unlocks design and material opportunities for the aviation industry. 

[22:40] The challenges related to additive manufacturing that keep Tim up at night. 

[30:50] Promising advances in additive manufacturing that will change the future of aviation. 

[37:27] How to raise awareness and implement additive manufacturing within an organization. 

Resource Links: 

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Follow the Additive Snack Podcast on Youtube 

JetZero 

Tim Berry on LinkedIn 

What used to be known as rapid prototyping is slowly becoming a long-term strategy for the manufacturing industry. Brands and manufacturers who integrate additive manufacturing (AM) based on solutions for pain points are much more likely to leverage additive’s unique design language capabilities. 

To discuss additive’s endless possibilities, Host Fabian Alefeld speaks with the Founder and Chief Operating Officer (COO) of SNL Creative Inc., Shawn Zindroski. With over three decades in the industry, Shawn reflects on innovations that shaped his career and the AM projects that will shape the future of manufacturing. The conversation is an in-depth exploration of growth strategies, and how AM can impact industries, individuals, and brands. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[2:00] From model maker to show cars, Shawn has a passion for creative solutions.  

[14:00] In 2008, Carbon Kids was the first customizable product from SNL Creative. 

[20:20] Fundamental lessons learned from creating the airless basketball for Wilson Sporting Goods. 

[24:24] Step-by-step production process including quality control measures for AM. 

[35:06] The time is now for industries to embrace additive manufacturing.  

[42:20] Nano-technology, automation, and robotics are the trends leveraging additive manufacturing. 

Resource Links: 

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Follow the Additive Snack Podcast on Youtube 

SNL Creative Inc. 

Shawn Zindroski on LinkedIn 

Additive manufacturing (AM) is transforming the tool and die industry by enhancing traditional processes and enabling intricate cooling structures in plastic injection molding that only AM can achieve. How will this technology reshape the future of tool and die manufacturing? 

To discover AM’s place in the tool and die industry, Host Fabian Alefeld speaks with Vilas Ravindra Dulipeta, Manager of the Additive Manufacturing Group at Canada’s AarKel Tool & Die Inc. They discuss AarKel’s unique innovations in plastic injection molding design, breakthroughs from past mistakes, and the secure role of additive in customer solutions such as EVs. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[3:19] Early in their AM adoption period, AarKel made some beautiful magnetic mistakes. 

[10:06] AM offers efficient cooling structures that improve cooling times for tool and die-casting production. 

[22:32] AM enables early process innovations in EV programs with the ability to create design parameters. 

[25:43] How AM allows for engineered porosity in the injection molding process. 

[36:58] While cost and education are challenges, additive offers Aarkel real benefits. 

Resource Links: 

EOS 

AarKel Tool & Die Inc. 

Vilas Ravindra on LinkedIn 

Connecting manufacturers with end users makes a big impact in the industrial manufacturing space but building a manufacturing supply chain takes time. Machine learning and AI can help create a predictive supply chain management platform that will make manufacturing more accessible and help companies reduce complexity within their operations. 

To discover a new digital platform for advanced industrial manufacturing, Host Fabian Alefeld speaks with Markus Seibold, co-founder and CEO of MakerVerse. MakerVerse is an interface between additive manufacturing (AM) and other manufacturing technologies that offers auto-quoting technology to on-demand manufacturers leveraging machine learning and AI. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[1:42] MakerVerse is the ‘Amazon’ of industrial advanced manufacturing. 

[6:28] MakerVerse’s mission is to create efficiencies in on-demand manufacturing. 

[13:03] How scale-up and midsize companies benefit from the MakerVerse platform. 

[21:33] Machine learning and AI were used to create MakerVerse’s advanced auto-quoting tool. 

[31:46] Predictive supply chain management is the future. 

Resource Links: 

EOS 

MakerVerse 

Markus Seibold on LinkedIn 

Penn United Technologies Inc. is a manufacturing company making quiet waves by integrating conventional manufacturing with additive manufacturing (AM). They have been able to integrate AM technologies wisely and organically for a steady growth trajectory. 

To discover how Penn United curated its growth journey, Host Fabian Alefeld speaks with Penn’s Project Manager, Jake Jones. Jake shares how Penn finds its engineering resources, manages production, and their Design for Manufacturing customer training. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[1:47] Penn United has a diverse history in various materials and manufacturing techniques. 

[7:27] How Penn integrates AM into their traditional subtractive manufacturing platforms. 

[12:44] Finding engineering resources, building talent, and managing AM production and teams at Penn United. 

[19:13]  Penn's competitive advantage is their ability to customize parameters to complex geometries swiftly. 

[26:20] Specialized growth opportunities in additive manufacturing. 

[28:51] Penn’s Design for Manufacturing training. 

[30:55] What Jake expects from AM in the future.  

Resource Links: 

EOS 

Penn United Technologies Inc. 

The nuclear industry is an underestimated technology that has a substantial impact on daily life. With an uptime average of ninety-three percent, nuclear power plants in the U.S. are three times more reliable than low-carbon technologies. Plus, that reliability makes the technology a smart choice to use as a backbone for future grids. 

To gain a wider understanding of nuclear power and the future role of additive manufacturing (AM) in it, Host Fabian Alefeld speaks with the Global AM Program Leader of Westinghouse Nuclear, Adam Travis. Along with other achievements in the AM space, Adam and Westinghouse recently celebrated the printing of their 1000th fuel flow plate for use in the nuclear industry. Adam shares Westinghouse’s AM journey and provides a glimpse into what is next for Westinghouse in the realm of nuclear power. 

Comments about the show or wish to share your AM journey? Contact us at [email protected]. The Additive Snack Podcast is brought to you by EOS. 

Key takeaways: 

[1:17] Nuclear is the best backbone for low-carbon grids. 

[6:47] AM helps design and manufacture safety-related parts for nuclear power plants. 

[23:52] An AM part was created to offer critical fuel supply diversity for Ukraine. 

[28:27] Westinghouse’s additive manufacturing journey. 

[38:35] Future AM applications at Westinghouse. 

Resource links: 

EOS 

Westinghouse Nuclear 

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 [email protected]. 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: 

EOS 

Save a Spine 

MIGN Design 

Dr. Baron Lonner