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 

The ultimate goal for additive manufacturing (AM) is for those creating, building, and designing for our future to reach for AM as another tool in their toolbox as easily as they would a traditional manufacturing method. To build this trust and knowledge of industrial 3D printing, countless hours of research are necessary.  

To learn more about the research being performed at Auburn University that is shaping the future of AM, Host Fabian Alefeld speaks with a distinguished AM figure, Nima Shamsaei. Nima is a Philpott-West Point Stevens professor at Auburn University and Director of the National Center for Additive Manufacturing Excellence (NCAME). At NCAME, Nima and his team are at the forefront of research and technology and are actively studying the fracture and fatigue behavior of AM materials. In addition, a joint project with the US government and Auburn University is supporting manufacturers to create components for NASA. 

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: 

[1:39] An interest in mechanical properties led Nima from automotive to pushing the AM envelope with NASA.  

[6:33] How Nima detects the fatigue behavior of additive materials.  

[9:31] Three challenges of collecting and leveraging additive material data.  

[16:19] When cost is not an issue, leveraging additive design maximizes its full potential. 

[19:48] Part classifications are based on qualification complexities and the consequence of failure. 

[23:21] A joint effort by the US government, Auburn University, and NASA support manufacturers to create parts NASA can use. 

It's clear that AI and additive manufacturing (AM) are a natural marriage of innovative technologies. As more companies focus on solutions that fortify the supply chain and increase the speed of engineering ingenuity, AM adoption will continue to accelerate.  

Today, host Fabian Alefeld speaks with the co-founder and CEO of 1000 Kelvin, Omar Fergani. 1000 Kelvin is a company at the forefront of the AI-driven revolution in the AM industry. Omar explains the depths of the innovation driven by 1000 Kelvin, the pivotal role that AI plays in industrial 3D printing, and how the AMAIZE co-pilot helps engineers to reduce design time and engineer onboarding.  

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: 

[1:18] 1000 Kelvin’s mission and how it plans to solve additive manufacturing’s biggest challenges. 

[6:26] How implementing a materials processing discipline will move additive manufacturing to serial production. 

[10:41] 1000 Kelvin’s AMAIZE is a co-pilot engineering tool and thermal management platform.  

[12:58] On a macro level, AMAIZE helps to onboard new engineers.  

[19:45] How the co-pilot integrates into the design workflow.   

[22:09] Business use cases support the growth of AM spare parts and fortify the supply chain. 

[26:03] The limitations and advantages of AI in AM.   

Space exploration and additive manufacturing (AM) are accelerating rapidly. SpaceX was able to reach orbital velocity with its latest starship launch, providing beautiful imagery upon its reentry. Rocket Lab had its 45th launch, with 22 additional launches planned for this year, and the first metal 3D printer installation on the International Space Station (ISS). With these accomplishments achieved, where will AM fit into our space journey's future? 

To find out, Host Fabian Alefeld ventures into the final frontier with a space roundtable with an all-star panel, featuring Paul Gradl, Principal Engineer at NASA, Myles Keefer, Manager of Additive Manufacturing at Rocket Lab, Eliana Fu, Industry Manager of Aerospace & Medical at TRUMPF, and Advenit Makaya, Advanced Manufacturing Engineer at the European Space Research and Technology Centre of the European Space Agency. 

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: 

[2:28] Additive manufacturing is a critical component of space exploration.  

[5:50] Common additive manufacturing challenges in space applications. 

[10:57] Additive manufacturing adoption in Europe. 

[13:28] Challenges of materials development today, and in the future. 

[26:16] How to leverage additive manufacturing for new innovative projects. 

[40:30] Machine manufacturer pain points and challenges. 

[51:48] What is driving additive innovation in Europe? 

[1:00:17] How to inspire a new generation of manufacturing engineers. 

Resource links: 

EOS 

Rocket Lab 

TRUMPF 

SpaceX 

NASA 

European Space Agency 

Bike enthusiasts understand the importance of quality welds, dynamic suspensions, and low-maintenance bikes. But to have a bike custom designed to their unique specifications is a dream come true. Today’s guest not only builds custom bikes he designs the parts using additive manufacturing (AM). 

Today, host Fabian Alefeld speaks with the owner and founder of 44 Bikes, Kris Henry, and EOS’ Spencer Thompson. Kris shares his passion for creating custom bikes and describes how he uses the design and supply chain aspects of AM to make handcrafted custom bikes accessible to a larger user group. Spencer offers insights into the state of AM adoption by small business owners, highlights the partnership opportunities available to manufacturers, and shares the hurdles independent builders face in the AM space.  

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: 

[2:11] 44 Bikes was born of Kris’ love of bicycles and his passion for designing things. 

[8:48] The benefits of additive manufacturing in building custom bicycles. 

[20:07] 3D printing offers small shop owners and bike enthusiasts a whole new level of design. 

[26:29] Supply chain challenges and speed to market increase AM adoption in small businesses.  

[34:22] When only a few parts are needed, finding manufacturers to partner with is a big hurdle. 

[36:03] The lack of protocols or universal standards for additive manufacturing creates a huge learning curve for independent builders. 

Resource Links: 

EOS 

44 BIKES 

Spencer Thompson on LinkedIn 

 Are you curious about how the U.S. Department of Defense (DoD) uses additive manufacturing (AM)? The military’s innovative approach has a 30-year roadmap, which was authored by this week’s guest. 

In this special episode, host Fabian Alefeld speaks with LJ Holmes. LJ has one of the most diverse jobs in the AM industry. He is the Executive Director of Advanced Manufacturing Research and Engineering at Harrisburg University. His rich background in AM from its historical roots in the DoD to current uses and future applications. LJ describes his AM journey from the Army Research Center to Harrisburg University, how AM has evolved within the defense sector, and some undocumented stories of early use cases and current applications within the DoD. 

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: 

[1:50] LJ shares his journey to AM and the integration of AM at the Army Research Center and the Department of Defense. 

[11:47] Authoring the 30-year Additive Manufacturing Roadmap was the last project LJ completed for the Army Research Center.  

[17:15] Harrisburg University of Science and Technology offers students an advanced manufacturing curriculum and STEM-focused education.  

[26:35] Additively manufactured components may or may not have been used in military vehicles as early as the 2000s. 

[29:41] Additive applications for future civilian and military use. 

[42:17] During AMUG 2024, LJ will introduce a 50-foot-tall friction stir hybrid additive machine. 

Resource Link: 

EOS 

LJ Holmes on LinkedIn 

Harrisburg University of Science and Technology 

JDAMMIT.com 

ASTROA.org — AM Forward focus