Podcast
Additive Snack
Hosted by EOS · EN
Join host Fabian Alefeld and a range of guests as they discuss all things additive manufacturing (AM) and 3D printing news, with interviews and real-world stories to educate and entertain. Each episode, Fabian talks to AM experts, professionals in specialist fields, and 3D printing users from all walks of life to deliver a well-rounded view on the state of AM.
Cut through the confusion surrounding polymer and metal additive manufacturing solutions with our digestible, down-to-earth discussions that deliver insights into common mistakes and best practice tips so you can get a clear understanding of AM — layer for layer.
Whether you’re curious about 3D printing technology for the aerospace industry, a deep dive into post processing, or applications of injection molding — we leave no spare parts behind. We want to provide you with the additive insight needed to stay laser focused and leverage every opportunity 3D printing materials have to offer.
Join us for an Additive Snack and we’ll help you and your business achieve growth and success through the latest developments in AM.
No marketing B.S. and no product pitches. Just the education, inspiration and information you and your organization need to drive business growth, brought to you by global AM leader EOS.
Get ready to feed your AM knowledge and find your path to success!
31episodes
Episodes
Newest firstAll episodes
Inside GM's Additive Industrialization Center with Ante Lausic
1w ago01:00:33Tap to summarizeIn this episode, Fabian Alefeld sits down with Ante Lausic, Lead Process Engineer at General Motors' Additive Industrialization Center (AIC), to explore what it takes to successfully scale additive manufacturing (AM) in the automotive industry. Ante explains why automotive manufacturing demands more than innovative technology - it requires AM-native designs, cost-effective production, automotive-qualified materials, and repeatable processes capable of supporting high-volume manufacturing. He also shares how GM has evolved from using AM primarily for rapid prototyping to establishing the Additive Industrialization Center in 2020 to evaluate new technologies, validate production readiness, and strengthen collaboration across the supply chain.The conversation highlights real-world production applications, including the Cadillac Celestiq, which incorporates more than 130 AM components, such as a safety-critical binder-jetted stainless steel seatbelt guide and aluminum steering wheel trim. Ante also discusses the rapid growth of additive manufacturing for tooling, including die-casting inserts, plant fixtures, and end-of-arm tooling, and offers his perspective on where the technology is delivering the greatest value for automotive manufacturers today.01:56 Scaling AM in Automotive05:10 Value and Cost Reality07:27 GM Additive Center Origins11:02 Educating Engineers and Suppliers14:34 Celestiq AM Success Stories19:44 Supplier Freedom and Standards23:00 Tooling Inserts Big Wins27:50 End of Arm Tooling Growth29:36 Motorsports and F1 Links32:10 Aftermarket Digital Warehousing33:39 Materials and PPAP Hurdles36:14 PPAP Explained Simply38:43 Rethinking Qualification Costs41:07 Scaling to Corvette Volumes
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Why AM and Orthotics & Prosthetics are the Perfect Fit
2w ago01:13:57Tap to summarizeFabian Alefeld interviews certified prosthetist/orthotist and EastPoint Prosthetics VP Brent Wright about his career path into O&P, his shift from being anti-digital to adopting scanning and additive manufacturing, and the impact on patient care and global access. Wright describes traditional fabrication workflows (casting, plaster positives, vacuum forming thermoplastics for orthoses, and carbon fiber/resin layups for prostheses) as artistic but time-consuming, hazardous, and lacking records. His digital journey accelerated after a Guatemala trip with Life Enabled highlighted the need to scale care; he focused on scanning, digital modification, and later powder-bed fusion, moving toward SLS with materials like PK5000 and TPU. He emphasizes pressure casting for prosthetic sockets, the value of digital records for insurance, and how AM can change socket “dynamics” to improve comfort and heal wounds. The discussion also covers RADii’s data-driven fitting approach, Life Enabled’s mix of traditional and 3D-printed solutions (including pediatric feet), modular “kit” concepts for developing regions, and barriers to sensors/actuators in the US due to reimbursement.02:33 Brent Origin Story09:30 Why Go Digital11:17 Scaling Global Access17:32 Traditional O&P Workflow20:02 Casting And Fabrication Steps24:07 Digital Workflow And Scanning33:22 Benefits Of Digital Records36:36 Flexible Liner Heals Wound40:47 RADii Data Meets Craft46:06 Life Enabled Model01:01:50 Democratizing via Manufacturing01:08:01 Sensors vs Simplicity
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AM at a Crossroads: Incodema3D Proves What's Possible at Scale
3w ago00:41:32Tap to summarizeFabian Alefeld sits down with Sean Whittaker, founder, president, and CEO of Incodema3D, to discuss the company's journey from a sheet metal prototyping business to one of North America's largest metal additive manufacturing operations. Sean shares why he invested in metal AM early, how Incodema3D built a production-first business model, and what it takes to scale additive manufacturing beyond prototypes.The conversation explores the evolution of Laser Powder Bed Fusion (LPBF) technology, the importance of vertically integrated manufacturing, and how improvements in machines, materials, software, and Design for Additive Manufacturing (DfAM) are making production at scale a reality. Sean also discusses growing demand driven by reshoring, defense, aerospace, and energy applications, Incodema3D's specialization in aluminum thermal management components and high-volume Inconel production, and how AFM Capital's investment is accelerating expansion through new equipment, automation, and future U.S. manufacturing sites.Episode Chapters01:41 Sean's Origin Story 05:13 Taking the Leap into Metal Additive Manufacturing 07:05 From Prototypes to Production 08:07 The Advantage of Vertical Integration 10:54 The Maturity of Additive Manufacturing and DfAM 15:46 Thermal Management, Inconel, and Consumer Applications 19:21 Defense, Energy, and Replacing Cast Components 21:28 Accelerating Growth with AFM Capital 25:49 Cycle Times, ROI, and Production Flexibility 30:07 Automation and Building the AM Workforce 34:50 Reshoring, Expansion, and the Future of Production 39:50 Wrap-Up
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AM Rocket Engines and Space Nuclear Power with Omar Mireles
Jun 2301:58:30Tap to summarizeFabian Alefeld interviews Omar Mireles, Director of Manufacture and Materials at Space Nuclear Power Corporation (Space Nukes), about his career spanning NASA, Oak Ridge, and Los Alamos and how additive manufacturing (AM) reshaped space hardware development. Omar describes early exposure to SLS prototyping, graduate work in nuclear materials and propulsion, building nuclear materials labs at NASA Marshall, and later leading AM efforts for liquid rocket engines and refractory metals. He explains how AM accelerates iteration, enables complex geometries, part consolidation, and weight reduction, and where traditional methods still dominate depending on production rate. The conversation covers refractory metal challenges (supply chain, oxygen sensitivity, post-processing, inspection) and nuclear reactor basics, generations, and regulatory barriers to AM adoption. Omar outlines Space Nukes’ goal of delivering safe, affordable, reliable power anywhere in the solar system, noting heat rejection as a key space constraint, Krusty’s 2018 test heritage, potential AM roles in heat exchangers, and an aggressive ~2-year flight timeline depending on regulation and mission. 02:26 Omar Early Motivation 03:08 NASA Co-ops and First AM 07:59 Stirling Radiation Research 20:07 Refractory Metals AM Lab 21:31 Los Alamos to Space Nukes 25:14 Did AM Change Space Race 31:46 Where AM Flies Today 37:41 Rocket Engines Print vs Traditional 41:15 Refractory Alloys Challenges 46:39 Where Refractories Make Sense 47:05 Will Refractory AM Grow 49:39 NASA Metal AM Handbook Origins 56:37 How Nuclear Reactors Work 01:13:02 Additive Manufacturing in Nuclear 01:18:31 What Space Nukes Builds 01:19:36 Why Space Nuclear Power Matters 01:25:20 Why Space Needs Nukes 01:37:47 Krusty Test Proof 01:41:18 Heat Rejection Challenge 01:49:25 Timeline and First Missions
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The Manufacturing Comeback: Dean Bartles on Defense, AI, and the Next Industrial Revolution
Jun 200:57:48Tap to summarizeHost Fabian Alefeld interviews Dean Bartles, President and CEO of the Manufacturing Technology Deployment Group (behind NCDMM, Advanced Manufacturing International, and America Makes), about manufacturing’s evolution, defense industrial base challenges, and additive manufacturing. Bartles recounts his career from shop-floor machining and industrial engineering to international defense manufacturing programs and 31 years through successive owners culminating in General Dynamics, then leading NCDMM and forming a parent organization to expand technology deployment. They discuss consolidation and contracting barriers that pushed small/medium firms out of defense, productivity gains from automation, reshoring momentum driven by tariffs and new investment, and workforce shortages and training pathways via trades, community colleges, and SME/Tooling U. Bartles highlights AI for process monitoring and adaptive control in laser powder bed fusion, the promise of low-cost desktop FFF for drones, the need for shared data and improved repeatability, and sustainability efforts including the Additive Manufacturing Green Trade Association. 00:00 Welcome and Guest Intro 02:54 Dean Manufacturing Origins 04:18 Global Defense Career Path 06:05 Leading NCDMM and America Makes 10:44 Defense Base Decline and Industry 4.0 18:14 Reshoring and Global Models 22:17 AI Capital and Process Control 35:25 Open Data and Repeatability Challenge 38:24 Defense Adoption and Drone Boom 44:08 Workforce Pathways and Community Colleges 50:04 Sustainability and Greener AM 54:27 Closing ABL Always Be Learning
Transcribe →From Hypersonics to AI Workflows: How Ursa Major Is Scaling Rocket Production
May 2601:11:43Tap to summarizeFabian Alefeld welcomes back Thomas Pomorski of Ursa Major to discuss developments over the past year across three focus areas: hypersonics, solid rocket motors, and in-space propulsion. Pomorski reports more than nine hypersonic missions flown with the reusable, ~80% 3D-printed Hadley engine and two successful test flights of the storable Draper engine with AFRL, plus progress on Ursa’s LINX solid rocket motor manufacturing approach using additive for tooling and cases to enable flexible “unit cell” scaling. They cover key hypersonics challenges around affordability and manufacturability and why a storable liquid rocket approach can reduce testing complexity. Much of the conversation focuses on AI’s current value in development: rapidly prototyping slicer features and scan strategies, building data-fusion and monitoring tools via EOS APIs, and enabling small teams to operate with much higher productivity, while noting production validation remains challenging.00:00 Welcome Back Thomas01:48 Ursa Major Year Update02:37 Hypersonic Flight Milestones04:05 Solid Motors and LINX05:21 Additive Scale Up Tools06:39 Hypersonic Cost Challenge11:58 Solid Motor Unit Cells15:37 Additive Geometry vs Supply18:01 AI in Additive Workflows24:33 AI Productivity Multiplier29:33 Live Claude Slicer Demo35:13 Prompting Claude Code36:35 Sharing Team Workflows38:40 Production AI Readiness42:20 Slicer Feature Results44:49 Closed Loop Optimization46:46 AI Built Web Monitor52:59 Automation Roadmap01:00:12 Verifying Hatch Strategy01:03:07 Advice For Students01:08:29 Wrap Up And Thanks
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Printing Batteries, how AM is changing Battery Manufacturing and Performance
May 1500:52:56Tap to summarizeFabian Alefeld hosts Karl Littau, CTO of Sakuu, to discuss why rechargeable battery manufacturing has changed little in decades and how Sakuu is rethinking it with additive approaches. Littau explains conventional thick-film slurry coating and stacked anode/cathode layers, noting heavy use of copper and aluminum and high costs driven largely by bill of materials. He outlines battery basics (anode, cathode, electrolyte) and contrasts lithium-ion with solid-state concepts, where solids replace liquid electrolytes but face commercialization challenges. Sakuu’s initial product targets electrode coating by shifting from wet, solvent-based processes to dry powder-bed methods, enabling powder reclaim/reuse, removing toxic solvents, reducing equipment size (e.g., long drying ovens), and potentially increasing throughput. The conversation also covers future possibilities like multi-material patterning, arbitrary shapes, bipolar designs that reduce metal, and broader impacts on EVs, grid storage, and electrification. 00:00 Welcome and Topic01:32 Why Batteries Need Change04:13 Cost Drivers Today07:53 Sakuu Additive Approach13:09 Battery Basics Explained18:30 Dry Powder Manufacturing26:10 Speed and Footprint Gains28:47 Scaling and Supply Chain32:27 Future Shapes and Structures35:42 Solid State Readiness37:48 Sakuu Origin Story40:31 Roadmap and Industry Impact42:34 Electrification Future Vision49:48 Wrap Up and Thanks
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Simulation as an Enabler: Pan Michaleris & Erik Denlinger on the Evolution of Additive FEA
May 600:55:40Tap to summarizeFabian Alefeld hosts Pan Michaleris, founder of PanOptimization (PanX), and Erik Denlinger, co-founder and chief engineer, to discuss the evolution and role of simulation and finite element analysis (FEA) in additive manufacturing. Pan shares his background as a Penn State professor and entrepreneur (including a prior company acquired by Autodesk) and explains how simulation helps reduce costly trial-and-error builds by predicting distortion, temperature, stress, buckling, cracking, and recoater risks, while moving toward closed-loop manufacturing-to-design workflows and property prediction. Erik outlines PanX’s commercial capabilities - fast thermo-mechanical simulation for very large parts, distortion compensation, and dwell-time optimization - and describes proof-of-concept work on controlling melt quality and hardness via parameter modulation. They cover adoption in aerospace/defense and new space, qualification implications, integration with build-prep workflows (e.g., EOS/Velosis), and cautious, validation-focused views on AI surrogate models.00:00 Welcome and Episode Preview01:13 Meet Pan and Erik01:59 Pan’s Journey to PanX03:59 Erik’s Origin Story05:10 FEA History and the Elephant Test08:32 Why Additive Needs Simulation10:23 Closing the Design Manufacturing Loop14:33 PanX Today Core Capabilities17:30 From Distortion to Material Properties20:25 Making Simulation Usable for Engineers27:06 Workflow Integration and Automation29:44 From Failures to Design30:41 Who Uses PanX Today32:41 Simulation for Qualification35:17 Layerwise Parameter Control38:51 Why FEA Is Hard41:38 AI and Surrogate Models46:53 Future Material Tailoring48:37 Roadmap Workflow Integration52:27 Closing Thoughts and Wrap
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The State of AM in Asia
Apr 1000:59:09Tap to summarizeHost Fabian Alefeld speaks with Japan-based additive manufacturing consultant Peter Rogers about the state of additive manufacturing across Asia Pacific. Rogers contrasts Japan’s advanced but risk-averse manufacturing culture - strong in incremental optimization, with slower certification (notably medical) and limited defense budgets - with faster-moving but smaller markets like Australia/New Zealand, where mining drives demand for rapid, remote part supply. They discuss China’s manufacturing scale and government support, its growing dominance in desktop FDM, and how low-cost Chinese metal PBF machines can win and retain service-bureau business despite Western strengths in quality and productivity. Singapore is highlighted for academia and MRO, while Korea spans shipbuilding, semicon, automotive, and defense. Southeast Asia is still production-focused with limited local R&D, whereas India is rising as an English-speaking engineering and R&D hub for global OEMs. Both see lowering costs and AI enabling broader, consumer-facing AM applications.00:00 Welcome and Guest Intro01:49 Peter Rogers Background03:32 Moving to Japan05:12 APAC Additive Overview09:23 China Manufacturing Dynamics13:27 Reshoring and Kaizen Mindset18:45 Traditional Skills vs Additive20:57 Japan Nearing Inflection Point25:06 Top APAC Applications29:02 Japan Korea Industry Mix30:31 China Scale And Funding33:18 FDM Race To Bottom34:27 Bambu Ecosystem Advantage36:53 Metal AM Price Expansion38:23 Chinese Metal Machines Case40:30 Competing On Productivity44:10 Southeast Asia Adoption47:06 India RnD Powerhouse49:46 Future Consumer Breakthroughs52:40 Japan Pushing DED Limits55:30 AI Lowers Barriers57:13 Wrap Up And Farewell
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From Fashion to Metal AM: Scaling Additive Manufacturing into Production
Mar 2500:58:46Tap to summarizeHost Fabian Alefeld interviews Erin Mastroni, President and founder of I3D Manufacturing (founded 2013), about building one of the largest additive-focused contract manufacturers and the industry’s shift from prototyping to production. Mastroni describes moving from fashion retail and trend forecasting to an MBA in sustainable business, spotting production AM as a key trend, and launching a metal powder bed fusion business in Oregon with limited traditional manufacturing experience. She recounts early funding challenges, using SBA/New Market Tax Credits, and landing Blue Origin as an early customer, which helped establish I3D as a fast-moving development partner known for tackling difficult materials like titanium and new nickel alloys with EOS. I3D grew from 5 people and two machines to two campuses, ~30 machines, and 54 employees, is launching an internal “I3D Academy,” navigated a severe COVID revenue drop without layoffs, and was acquired in 2023 by BTX Precision (L Squared Partners), expanding into turnkey CNC and broader capabilities while discussing PE’s role, production scalability, and emerging AI opportunities.00:00 Podcast welcome01:47 Fashion to additive04:27 Funding and mission06:52 Blue Origin breakthrough08:27 Becoming a dev partner12:19 I3D today scale15:29 Growing talent academy17:05 Growth phases and pandemic20:22 Acquisition and turnkey expansion22:06 Private equity tipping point27:43 Private Equity Momentum28:41 Flow Driven Applications32:54 Supply Chain Use Cases35:12 Scaling Production Know How40:21 One Stop Shop Strategy43:14 Customers Get Smarter47:31 Next Wave Breakthroughs53:03 AI In Additive Manufacturing57:25 Closing Thanks
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