In this episode of the Additive Snack Podcast, host Fabian Alefeld welcomes back Paul Gradl, Principal Engineer at NASA, for a deep dive into the latest advances and challenges in additive manufacturing. Paul shares how NASA has expanded the range of available materials, pioneering alloys like GR COP and GRX 810 for extreme environments, and how these innovations are now being used in industries beyond aerospace. 

The conversation covers the rapid acceleration of material development through advanced modeling and early AI adoption, the technical hurdles of scaling up to larger parts, and the realities of additive manufacturing in space—from lunar construction to the potential of asteroid mining. Paul also discusses the importance of learning from failures, NASA’s commitment to public data sharing, and his passion for mentorship and STEM education, both at work and at home. Whether you’re an industry veteran or new to additive, this episode offers valuable insights and inspiration. 

Sign up for the NASA Metal AM Master Class today: Metal AM Master Class with NASA | EOS Store - US 

• 2:00 - The Evolution of Additive Materials 
  NASA is expanding material options and redefining what’s possible with additive. 
• 7:45 - Material Highlights & Cross-Industry Applications 
  Paul discusses GR COP, GRX 810, and their applications beyond aerospace. 
• 13:45 - AI, Machine Learning & Accelerating Alloy Development 
  AI and modeling are accelerating how new alloys are developed. 
• 17:50 - Scaling Up: Big Parts & NASA’s Role 
  NASA is driving the shift toward larger, room-sized additive parts. 
• 23:45 - How Much of a Rocket is Additive? 
  Additive plays a growing—but complementary—role in rocket manufacturing. 
• 26:30 - Additive in Satellites, Space, and In-Space Manufacturing 
  Additive is key to building satellites, landers, and lunar systems. 
• 32:00 - Lunar Regolith, Moon Dust, and Asteroid Mining 
  NASA explores using Moon dust and asteroids for future construction. 
• 36:50 - Learning from Failure: Engine Test Stand Story 
  A test stand failure highlights the importance of understanding the process. 
• 43:45 –Metal AM Master Class Announcement 
  Details on Paul and Omar’s upcoming metal AM master class. 
• 46:30 - Mentorship, STEM, and 3D Printing at Home 
  Paul shares how he supports STEM education at NASA and at home. 

In this episode of the Additive Snack Podcast, host Fabian Alefeld is joined by Thomas Pomorski, Director of Additive Manufacturing at Ursa Major. Tom discusses his extensive background in additive manufacturing, including his work at Bechtel Plant Machinery and Penn United. He shares insights into Ursa Major's journey in scaling propulsion manufacturing for space and defense, emphasizing the importance of insourcing, quality systems, and the iterative approach in additive development. 

Tom delves into the challenges and solutions in scaling additive manufacturing, including complex parameter strategies, automation, and flexible manufacturing. He also highlights Ursa Major’s products, such as the Hadley and Draper engines, and the company's innovative approach to solid rocket motor manufacturing. The episode concludes with Tom's advice for companies looking to scale additive manufacturing operations and a look into the future of the industry.

01:46 Tom's Journey into Additive Manufacturing

02:04 Early Career and First Additive Roles

04:38 Joining Ursa Major and Initial Challenges

10:11 Vertical Integration and Scaling Challenges

20:14 Advanced Additive Strategies and Collaborations

26:28 Automating Build Setups with Python

26:58 Challenges in Hiring Additive Process Engineers

28:06 Building a Passionate and Skilled Team

29:30 Leveraging Local Talent and Resources

31:17 Collaborating Across the Aerospace and Defense Industry

32:50 URS's Product Portfolio and Additive Manufacturing

35:34 Flexible Manufacturing for Solid Rocket Motors

39:07 Future Developments in Additive Manufacturing

41:35 The Importance of Material Development

46:29 Scaling Operations and Advice for Newcomers

In this episode of the Additive Snack Podcast, host Fabian Alefeld is joined by Mahdi Jamshid and Scott Sevcik of the ASTM Additive Manufacturing Community to discuss significant trends and insights within the additive manufacturing industry. They delve into the history and evolution of the Wohlers Report, various advancements in different sectors like defense and consumer products, and the impact of geopolitical factors such as trade policies on the industry. The discussion also covers the maturity of additive manufacturing, the role of standards and certifications provided by ASTM, and future growth projections. Mahdi and Scott offer a comprehensive view of how the industry has evolved and what to expect in the coming years. 

01:47 History and Evolution of Wohlers Report 

02:54 Wohler Report's Acquisition and Transformation 

06:35 Consulting and Advisory Services 

13:46 Emerging Trends in Additive Manufacturing 

30:28 Challenges and Slowdowns in the Industry 

38:01 Scalability in Hardware vs. Software Investments 

39:07 Impact of Politics and Trade Policies on Additive Manufacturing 

39:55 Complexities and Uncertainties in Global Supply Chains 

46:18 European Union's Defense Spending and Additive Manufacturing 

52:50 Role of Standards in Additive Manufacturing 

01:02:44 Future Trends and Industry Growth Projections 

01:14:41 Conclusion and Final Thoughts 

In this episode of the podcast, host Fabian Alefeld interviews Chris Holshouser, Deputy Program Director of Maritime Systems at BlueForge Alliance. They discuss the Navy's ambitious projects, focusing on advanced technologies like additive manufacturing, supply chain optimization, and workforce development. Chris elaborates on the challenges and goals associated with the Columbia and Virginia class submarines, the importance of enhancing the maritime industrial base, and the need for skilled labor in manufacturing. The conversation also touches on the establishment of the Additive Manufacturing Center of Excellence, partnerships with various organizations, and the long-term vision for modernization and technological integration in shipbuilding. 

More information on the Maritime Industrial Base Additive Manufacturing Excellence training available here.  

01:23 Meet Chris and BlueForge Alliance 

02:37 Mission and Impact of BlueForge Alliance 

04:32 Understanding the US Navy's Triad and Submarine Classes 

07:03 Challenges in Modernizing the Industrial Base 

12:30 Role of Additive Manufacturing in the Navy 

19:26 Understanding Metallurgy in Welding 

19:40 Applications and Supply Chain Impact 

21:22 Certification and Qualification Process 

22:42 Additive Manufacturing in Practice 

24:19 Challenges and Opportunities in Additive Manufacturing 

28:17 Interdisciplinary Nature of Additive Manufacturing 

30:18 Evaluating Parts for Additive Manufacturing 

32:54 Advancements in Additive Manufacturing 

37:01 Future Directions and Call to Action 

In this episode of the Additive Snack Podcast, host Fabian Alefeld interviews Alex Oster, Director of Additive Manufacturing at Autodesk. The conversation spans Alex's journey from his early career in 1998 in Bavaria to his current influential role at Autodesk. They delve into the evolution of the additive manufacturing industry, from its early days to the current market dynamics and innovations, including the impact of AI and simulation technologies.  

Alex shares stories from his time at FIT and Netfabb, including the challenges and innovations they faced. He explains Autodesk's strategy of integrating specialized tools into one cohesive platform, Fusion 360, which offers comprehensive solutions for both industrial and mass-market applications. They also discuss the crucial role of workforce development and the importance of making advanced manufacturing tools accessible to students and professionals. The episode concludes with thoughts on the future of additive manufacturing and the impact of AI on the industry. 

01:09 Alex's Journey into Additive Manufacturing 

02:32 Early Industry Challenges and Innovations 

07:29 Growth and Development of NetFabb 

12:16 Impact of FDM Revolution 

21:32 Autodesk Acquisition and Integration 

30:13 Fusion 360: A Comprehensive Tool 

37:31 Workforce Development and Industry Adoption 

47:15 The Rise of Low-Cost Machines 

48:29 The Evolution of Metal Additive Manufacturing 

49:43 Western Machine Vendors and Market Dynamics 

50:03 High-End Custom Machines and Industry Trends 

53:49 AI's Role in Additive Manufacturing 

54:44 Autodesk's Product Strategy and Market Position 

56:52 Simulation and Surrogate Modeling 

01:10:01 Challenges in Polymer Simulation 

01:11:30 AI and Computer Vision in Manufacturing 

01:14:30 The Future of Manufacturing Integration 

In this episode of the Additive Snack Podcast, host Fabian Alefeld welcomes Brad Rothenberg, CEO and founder of nTop, formerly known as nTopology. They discuss the evolution of additive manufacturing and nTop’s role over the past three to four years. Topics include the founding story of nTop, the concept of implicit modeling, and how design tools have rapidly changed. Brad shares insights on using nTop for aviation design, thermal management, and heat exchanger design, pointing out the shift from traditional CAD to innovative parametric modeling for effective engineering solutions. They also explore the future impact of AI on engineering and how nTop is integrating AI to enhance design processes. The episode closes with a look at educational resources and training for engineers new to nTop. 

1:37 The Founding Story of nTop 

05:07 Implicit Modeling and Design Evolution 

10:22 nTop's Impact on the Aviation Industry 

19:32 Thermal Management and Heat Exchangers 

31:05 Recreating Existing Models in nTop  

2:16 Intern Projects: Building Gliders and Drones 

33:44 Understanding Process Knowledge in 3D Printing 

34:59 Custom Blocks and Design Rules in nTop 

37:08 N Top's Role in Legacy and New Designs 

38:17 Future Roadmap: Integration and Simulation 

44:16 AI and Machine Learning in nTop 

57:54 Lowering Barriers for Engineers 

In this episode of the Additive Snack Podcast, host Fabian Alefeld welcomes Carolyn Schwaar, the editor of All3DP.com. Together, they explore current trends in additive manufacturing, the transition of hobbyists to professionals, and the role of platforms like All3DP and Kraft Cloud in the industry. Carolyn shares success stories from readers who have integrated 3D printing into their professional lives, the impact of tariffs on the industry, and the importance of reliable resources for learning about additive manufacturing. They also discuss the rise of specialized contract manufacturers and how the accessibility of 3D printing services is transforming various sectors. 

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. 

For more information about ALL3DP, visit their website and connect with Carolyn Schwaar on LinkedIn. 

01:51 Overview of All3DP.com 

03:01 Craft Cloud and 3D Printing Services 

04:41 Transition from Hobbyist to Professional 

07:48 Resources for Industrial Additive Manufacturing 

12:29 Contract Manufacturing Insights 

18:20 Global Trends and Tariffs Impact 

30:09 European Market and Defense Applications 

34:40 Favorite Additive Manufacturing Stories 

In this episode of the Additive Snack Podcast, host Fabian Alefeld explores the critical role of mathematics in additive manufacturing with guest Harshil Goel, founder, and CEO of Dyndrite. Harshil shares his unconventional entry into the additive manufacturing industry, driven by his deep background in mathematics and mechanical engineering. The conversation delves into how Dyndrite's software provides solutions for complex additive manufacturing challenges, from data preparation to materials and process development. 

Harshil also discusses various customer success stories and how their software helps streamline qualification processes, ultimately enhancing productivity. Additionally, they discussed the upcoming Dyndrite roadshow aimed at educating users on advanced additive manufacturing techniques, featuring hands-on sessions and practical demonstrations.

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. 

For more information about Dyndrite’s innovative solutions, visit their website and connect with Harshil Goel on LinkedIn.     

01:17 Meet Harshil Go: From Mathematics to Additive Manufacturing

02:33 The Birth of Dyndrite: Solving Software Challenges

05:22 Understanding Dyndrite's Core Offerings

09:53 Dyndrite's Unique Approach to Build Preparation

15:07 Customer Success Stories and Real-World Applications

19:47 Empowering Engineers with Python Integration

23:04 Learning and Adapting to Dyndrite's Tools

26:51 Multilingual Proficiency and Family Background

27:36 Transitioning to Coding and Tool Integration

28:17 Optimizing Production with Dendrite

30:05 Challenges and Innovations in Qualification

33:20 Deep Dive into Aviation Qualification

39:17 Additive Manufacturing Industry Trends

43:09 The Role of GPUs and AI in Additive Manufacturing

45:59 Dyndrite Roadshow and Conclusion

In this episode of the Additive Snack Podcast, host Fabian Alefeld explores the importance of automating powder removal in the additive manufacturing (AM) process with Hemank Raj, Process Development Engineer from Solukon. They discuss how automating this process, which may seem minor, is crucial for scaling production and ensuring high-quality outputs in the industry. Hemank provides insights on the background of Solukon, which evolved from an engineering consultancy to a key player in automated depowdering solutions. They delve into the technical aspects, including the steps and benefits of automated depowdering, the safety advantages, and the key factors to consider in the design and production stages. 

The episode highlights the significant impact of automated de-powdering on sectors like aerospace, medical, automotive, and energy by improving efficiency, safety, and reliability. Hemank also shares upcoming innovations, such as integrating robotic arms to further enhance the de-powdering process.

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. For more information about Solukon, visit their website and connect with Hemank Raj on LinkedIn.

01:00 Guest Introduction: Hemank Raj from Solukon

01:14 The Importance of Automating Powder Removal

02:00 Solukon's Journey and Market-Driven Innovation

03:52 Automated Depowdering Process Explained

08:49 Challenges and Solutions in Depowdering Large Parts

14:18 Ensuring Quality and Safety in Depowdering

15:39 Programming and Customizing Depowdering Systems

21:43 Design Considerations for Automated Depowdering

23:42 Understanding the L by D Ratio

24:05 Smooth Internal Channels and Surface Roughness

24:46 Introducing SPR Pathfinder Software

26:04 Design Considerations and Best Practices

26:50 Advanced Depowdering Techniques

29:12 Post-Depowdering Steps

33:46 Challenges with Specific Materials

37:12 Industry Applications and Innovations

42:01 Future of Automated Depowdering

In a special live episode of the Additive Snack Podcast recorded at RAPID + TCT 2025 in Detroit, host Fabian Alefeld welcomes Dr. Andreas Vlahinos, a leading expert in design and additive manufacturing. The conversation spans the evolution of design for additive manufacturing over recent years, focusing on advances in simulation-driven design and the integration of implicit and voxel-based tools within CAD environments. Dr. Vlahinos shares insights on overcoming challenges in the industry, his experience with impactful projects like custom medical implants and high-performance heat exchangers, and the importance of collaboration between design and manufacturing teams. The episode also touches on fostering innovation and inspiring the next generation of engineers to embrace the transformative possibilities of additive manufacturing. 

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.  For more information about Advanced Engineering Solutions, visit their website and connect with Dr. Andreas Vlahinos on LinkedIn.   

00:23 Meet Dr. Andreas Vlahinos: A Pioneer in Additive Manufacturing 

01:26 Evolution of Design for Additive Manufacturing 

03:24 Simulation-Driven Design: The Game Changer 

06:34 Challenges and Progress in Additive Manufacturing Tools 

10:03 Exciting Projects: From Heat Exchangers to Life-Saving Implants 

14:28 Designing Efficient Heat Exchangers 

22:24 Design Variables and Exploration 

23:39 Manufacturability Challenges 

25:44 Manufacturing Process Simulation 

28:21 Collaboration in Design and Manufacturing 

30:04 Passion and Inspiration in Engineering 

35:44 Innovative Design Examples