How can a defect smaller than a human hair cause an aircraft system to fail?

In this episode of Manufacturing Runs The World, Justin Schnor sits down with Tessa Axsom, Product Marketing Manager at Fictiv, mechanical engineer, manufacturing expert, and metallurgy enthusiast.

Tessa shares her unique journey through aerospace manufacturing, metallurgy, CNC machining, product development, failure analysis, and advanced manufacturing.

One of the most fascinating stories from this conversation involves a microscopic defect measuring only ten microns that affected a critical electrical contact used in an aircraft communication system. The investigation revealed how an incredibly small manufacturing issue could have enormous consequences for an entire aerospace system.

This episode explores:

• Metallurgy and the science of metals

• Aerospace manufacturing challenges

• Failure analysis and root cause investigations

• Why small defects create major system failures

• CNC machining and manufacturing processes

• Product development and prototyping

• Manufacturing innovation

• Engineering careers

• Mentorship in manufacturing

• Why hands-on experience matters for engineers

• Design for manufacturing principles

• The future of advanced manufacturing

ABOUT THE GUEST

Tessa Axsom is the Product Marketing Manager at Fictiv and a mechanical engineer with experience in aerospace manufacturing, metallurgy, CNC machining, finishing processes, product development, and failure analysis.

hroughout her career, she has worked on aerospace components, medical applications, manufacturing processes, and engineering investigations involving material performance and failure mechanisms.

ABOUT FICTIV

Fictiv is a global manufacturing and supply chain technology company helping innovators accelerate product development from prototype to production.Fictiv supports customers across aerospace, robotics, medical devices, consumer products, industrial equipment, and advanced manufacturing through a global network of manufacturing partners and engineering expertise.

FEATURED GUESTS

Tessa Axsom — Product Marketing Manager, Fictiv

Featuring: Rachael Brownell — Content Marketing Manager, FictivWhile Tessa leads most of the conversation, Rachael joins the discussion representing Fictiv's content and manufacturing storytelling efforts.

CHAPTERS

00:00 Meet Tessa Axsom

00:38 Why Manufacturing Is Misunderstood

01:15 Engineering, Marketing & Manufacturing

02:30 Falling In Love With Metallurgy

03:13 What Metallurgy Actually Is

03:44 Investigating Manufacturing Failures

05:20 The 10-Micron Aircraft Defect

06:41 Why Tiny Defects Cause Huge Problems

07:02 Working Across Aerospace, Robotics & Medical

08:13 Helping Innovators Build Products

09:41 From Idea To Production

11:31 Why Companies Switch Manufacturing Partners

12:14 How Fictiv Supports Different Industries

14:00 Mentorship For Young Engineers

15:00 Why Hands-On Experience Matters

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