3DPOD: Insight from 3D Printing Pros

So, it has been 200 episodes of the 3DPOD! That is incredible! We really didn’t think it would be this much fun and last this long. We’ve had incredible guests and still love doing this for you! We would like to thank you so much for your support over the last five years. Five years is a long time, and we really appreciate our loyal listeners and the time you have given us. We hope that you’ve laughed and learned, and we hope to have 200 more episodes!

About a decade ago, entrepreneur Graham Bredemeyer started Collider, a company that combined the best of 3D printing with injection molding. Now he runs CADChat, which hopes to make sharing and discussing CAD files more social. The young entrepreneur also talks about his time at Zverse, Shapeways, Adaxis, and Essentium. This episode of the 3DPOD provides a look into entrepreneurship and a new generation that is more “3D printing native” than the engineers from before.

Neil Hopkinson, a pioneering 3D printing researcher, played a pivotal role in developing a body of research that is widely utilized today. He also invented High Speed Sintering (HSS), also known as Selective Absorption Fusion (SAF), and successfully commercialized this technology. This journey, of course, was a lengthy process, which he is now completing at Stratasys (Nasdaq: SSYS). We discuss powder bed fusion, the current state of research, and what it takes to bring a new technology to fruition.

Lithoz is a pioneer in the 3D printing of technical ceramics, initially using a ceramic-loaded stereolithography process and later adopting multiple technologies. Johannes Homa, a researcher turned entrepreneur, discusses his transition from academia to business. In this episode of the 3DPOD, our conversation covers ceramics, the development of technologies, and business growth. Johannes provides insight into Lithoz and shares how the company is advancing the use of a new class of materials.

Dietmar Hutmacher is a Professor and Chair in Regenerative Medicine at the Faculty of Engineering, School of Mechanical, Medical, and Process Engineering at Queensland University of Technology. He possesses extensive experience in 3D cell cultures, grafts, biomaterials, scaffolds, bone engineering scaffolds, biofabrication, and more. On this episode of the 3DPOD, we engage in a candid discussion about the hype surrounding bioprinting, the reality, and the forefront of bioprinting in patients.

Andy Jeffery is a long-time 3D printing veteran who has repeatedly introduced binder jetting technologies to new areas. Starting as one of the earliest adopters of this technology for filters, Andy has worked with materials such as glass, ceramics, wood, and more. Now at Marvel Labs, he is part of an initiative to develop cost-effective 3D printing methods for wood, coffee, and seaweed. Time and time again, Andy has taken his deep technological insight and repurposed it for potentially huge applications. His current projects could lead to products that reduce CO2 emissions and change consumption patterns.

David Dietrich‘s journey in 3D printing spans from materials engineering roles at Boeing and ORNL to his position as an engineering fellow at Honeywell, showcasing his extensive experience in metals and polymer manufacturing. Currently, David is part of PADT, a company specializing in the manufacturing and design of 3D printed medical devices, space components, and more. In this episode of the 3DPOD, Dietrich shares his insights into the evolution of 3D printing over the years, offering valuable lessons from his broad experience in the field.

Ricky Wildman is working on 3D printing pills, but, as Professor of Multiphase Flow and Physics at Nottingham, he does a whole lot more. His research encompasses the characterization of metal 3D printed components, laser scan strategies, regenerative medicine, and more. Given his broad exposure to various fields, Ricky’s perspective on additive manufacturing is notably more comprehensive than what is commonly encountered. What follows in this episode of the 3DPOD is an insightful conversation covering a wide range of topics, offering diverse viewpoints on numerous subjects.

François Minec began his career in polymers as an engineer. He then progressed to roles as a product and general manager in several polymer companies. Following this, he founded Advanc3D Materials, where he developed polymers for powder bed fusion. After the sale of this company to BASF, he took on the role of leading BASF’s additive manufacturing business before becoming the head of HP’s polymer 3D printing division. In this episode of the 3DPOD, we delve into polymers, the cost of 3D printing materials, strategies to advance the industrialization of 3D printing, and much more in a thorough discussion.

Amy Alexander leads the 3D printing initiatives at the Mayo Clinic. You’ll be astounded by the ambitious plans this hospital has for additive manufacturing. In this episode of the 3DPOD, Amy discusses the Mayo Clinic’s multi-year strategy to utilize powder bed fusion for printing metal implants, instruments, and devices in-house. Additionally, Amy elaborates on how her team is applying Additive Manufacturing within the hospital. In particular areas, like new device design, the team is indeed undertaking innovative activities. This is essential reading for anyone interested in the intersection of 3D printing and healthcare.

Ali Tamijani, a professor in the Department of Aerospace Engineering at Embry-Riddle Aeronautical University, has an extensive background in composites, tool pathing, and the development of functional 3D printed parts, primarily for the aerospace industry. He developed Novineer, a tool designed to simplify the editing and adaptation of complex files for additive manufacturing components. This tool allows parts to be optimized by significantly reducing the number of surfaces and volumes and tailoring them according to where strength and other specific properties are needed. Additionally, it ensures that parts are optimized in conjunction with the toolpaths. Novineer is a distinct product in the field of advanced additive components, and we discuss its development and applications with Ali.

Shannon VanDeren is a consultant in the 3D printing industry, focusing on implementation and integration for her company, Layered Manufacturing and Consulting. For nearly ten years, she has been involved with the Additive Manufacturing Users Group (AMUG), culminating in her role as the organization’s President. Her extensive career includes positions at 3D Systems, Materialise, and other renowned firms in the additive sector. In this episode of the 3DPOD, Shannon shares her insights into the additive industry based on her experiences in the 3D printing field ahead of the upcoming AMUG event in Chicago, March 10-14, 2024.

Clare DiFazio’s journey into the 3D printing industry was serendipitous, yet her involvement at critical moments has significantly influenced the sector. Her position as Head of Marketing & Product Strategy at E3D offers a distinctive insight, as the company stands as the sole major supplier of aftermarket 3D printer components and the primary producer of nozzles for numerous material extrusion OEMs. DiFazio joined E3D during its nascent stages, contributing through periods of remarkable growth and challenging times, including tragic events. Alongside sharing her personal narrative, she provides valuable advice on scaling a hardware business and fostering unity during difficult periods.

Jeremy Pullin, an additive manufacturing (AM) veteran with decades of experience, is currently at the leading medical firm, Sartorius Group. He has been instrumental in setting up engineering centers and has significantly contributed to the development of metal 3D printing over the years. In an open-hearted conversation, he shares insights into the application of 3D printing in both industrial and medical sectors. We delve into topics such as materials, processes, software, files, and the various challenges that come with implementing additive technologies. Pullin’s learned and very direct approach is particularly refreshing; he candidly discusses the hurdles faced in the adoption of AM, offering a comprehensive and honest perspective on the state of the field.

John Kawola was one of the initial employees at Zcorp, a pioneering 3D printing company known for manufacturing color parts that was eventually acquired by 3D Systems. Subsequently, Kawola rejoined the 3D printing sector to lead Ultimaker’s invasion into the US market. Not stopping there, he later assumed leadership at BMF, a company specializing in the production of micro-sized parts using digital light processing technology. BMF is carving out a niche for itself while also commercializing applications that utilize its innovative technology—a strategy that, in our opinion, should be more widely adopted.

Stefan Ritt, a expert in 3D printing veteran, has contributed significantly to numerous additive manufacturing committees and standardization initiatives. For twenty years, he was a pivotal figure at SLM Solutions, joining the company during the nascent stages of its metal 3D printing venture. His tenure spanned the major phase of internationalization and expansion. Consequently, on this episode of the 3DPOD, we had the privilege of hearing Stefan’s tales from the formative years, as well as his insights on the current state of the industry.

Chris Prue, who initially honed his skills in the Quality department at GE, later transitioned to GE Aviation, where he ascended to the role of Additive and Process Manager. His career journey then led him to AddUp, followed by a move to UPM Additive. UPM distinguishes itself in the powder bed fusion sector through a novel approach. Instead of focusing on selling metal powder, the company has carved out a specialization in the creation, resurfacing, and customization of build plates for metal 3D printing. In this episode of the 3DPOD, we dive into the nuances of build plate optimization and the intricacies of the metal 3D printing industry.

Greg Morris, CTO of advanced manufacturing provider Zeda Technologies, is a true industry leader in 3D printing. Decades back, he made his initial family metals firm, Morris Technologies, into an early adopter of metal 3D printing in the U.S., thus helping America industrialize metal additive though his work with GE. Morris Technologies was ultimately acquired by GE. Now, with Zeda, he is sure to make an impact as well. In this episode of the 3DPOD, Morris is humble as he discusses the unsung engineers that really performed the trailblazing work. There are a number of lessons in this show about how to build an innovative organization and how to survive.

Sherri Monroe is the Executive Director of the Additive Manufacturer Green Trade Association (AMGTA). There’s a growing curiosity about the environmental aspects of 3D printing. Is it truly “green”? Understanding how to measure sustainability and promote it is crucial in this context. When one process proves superior in certain aspects compared to others, what steps should be taken? This leads to a broader question: how can companies be encouraged to adopt greener practices? Moreover, does 3D printing have the potential to drive more companies towards eco-friendly operations? We discuss these topics and more in this episode of the 3DPOD.

Hans-Alfred Breuninger, with a background as a strategy consultant, has specialized in 3D printing after many years in his initial field. He has collaborated with leading original equipment manufacturers (OEMs) such as Stratasys, and engaged in projects for industrial clients and prospective 3D printing users. In this episode of the 3DPOD, we delve into strategies for encouraging companies to adopt 3D printing, explore the challenges involved, and discuss the expected evolution of the market. Hans-Alfred expresses concern over the German industrial base, highlighting apprehensions about Chinese companies potentially outpacing German ones in the 3D printing sector. We are particularly impressed with Bambu Lab, anticipating its potential to outperform many competitors. The three of us also share our insights on strategies to effectively compete with Bambu. While this episode starts off slowly, it blossoms into a compelling discussion as it progresses.

Nestled beside a potato field, JawsTec‘s location may not raise eyebrows in the state known for its spuds, but the competitive spirit of the 3D printing service bureau certainly might. Oscar Klassen, the company’s founder and CEO, delves into the origins of JawsTec, charting the company’s growth and sharing his aspirations for its future. His perspectives on automation and post-processing are notably unconventional. Oscar also elaborates on his ambitious goals for the company. In our discussion, he envisions the road ahead for his business, considering the factors that propel and impede its progress.

Seven years ago, Jonas Galle began his journey to develop a molten metal 3D printing technology. Since then, his young startup, ValCUN, has been on a wild ride The company has introduced a unique method for 3D printing aluminum using inexpensive feedstock and recently launched a user-friendly machine for laboratories, with plans to release one geared towards production. ValCUN aims to execute 3D printing for mass manufacturing in sectors such as power electronics and automotive. In this episode of the 3DPOD, Jonas candidly shares the challenges he faced in securing funding, evolving as an entrepreneur, and more.

After a lengthy tenure at GE, Juan Mario Gomez took an unexpected turn, launching a metal 3D printing venture, Xact Metal. In this episode of the 3DPOD, he shares his experiences at GE and his subsequent journey. This includes what it takes to produce affordable metal powder bed fusion systems, as well as the challenges of initiating and sustaining a business in this field. His insights offer valuable lessons for a broad audience.

Gabe Linke serves as a technical specialist at Children’s Nebraska hospital, where he plays a pivotal role as a bridge between conceptual ideas and their tangible, printable counterparts. His expertise lies in transforming patient scans into makable models. He is among the select few with extensive experience in operating a hospital 3D printing lab. While such labs were once a rarity, they are now experiencing rapid expansion. Many hospitals are increasingly adopting 3D printing to create medical models for various purposes, including teaching, education, patient explanations, and planning complex surgeries. In this episode of the 3DPOD, Gabe guides us through his workflow, sharing insights about the 3D printers he utilizes and highlighting aspects that are crucial to him. He also shares insights into what matters to the doctors he collaborates with and their patients, showcasing the integral role of 3D printing in modern medical practices.

As CEO, Chaw Sing Ho spearheads National Additive Manufacturing Innovation Cluster (NAMIC), Singapore’s national initiative for 3D printing. In our in-depth conversation with him on the 3DPOD, we explore the nuances of Singapore’s ecosystem and discuss strategies to foster additive manufacturing in various countries. We delve into what Singapore excels at in this field, along with its future aspirations. The dialogue also examines the potential impact of 3D printing on Singapore, a trade-centric entrepôt. Our discussion offers both detailed insights into key areas and a broader, helicopter view of the steps needed to advance 3D printing further. It’s an engaging talk that we believe you’ll find enjoyable!

Ben Holmes shares his venture into developing a potentially game-changing medical device technology. His company, Nanochon, aims to alleviate cartilage problems with an implant that initially substitutes the cartilage, then fosters natural body repair. Given that cartilage issues plague millions, this innovation holds promise for being both lucrative and impactful. Conditions like osteoarthritis significantly impair the quality of life for many. This narrative delves into the creation of the product and the ongoing journey of the startup. It’s important to note: Nanochon’s Chondrograft device has yet to receive approval for use in the United States.

Elias Stahl believes that his startup, HILOS, has the potential to transform the manufacturing industry. Starting with 3D printed shoes, he aims to integrate this technology with skilled labor, additional machinery, and knitting techniques to produce highly wearable footwear. Stahl envisions HILOS as a sustainable manufacturing platform that can serve various brands. The team’s expertise in manufacturing, combined with their skills in 3D printing design, positions them to excel in a unique market niche. Ultimately, Stahl hopes this technology will expand to a wide array of products.

Philip Lund-Nielsen entered the world of desktop 3D printing as a co-founder of a Danish reseller. Impressively, that reseller underwent a significant transformation to become COBOD, now one of the largest global companies in the construction 3D printing industry. On this episode of the 3DPOD, we sat down with Philip to discuss the potential of 3D printing in construction, covering topics from housing and infrastructure to concrete, sustainability, and future market trends.

Richard Hague, a pioneering researcher in the realm of additive manufacturing, now holds a position at the University of Nottingham. Besides his academic pursuits, he is also a co-founder of Reactive Fusion, a company committed to realizing groundbreaking applications of 3D printing in polyurethane and silicone. On this episode of the 3DPOD, our discussion with Professor Hague spans a wide range, exploring both the potential and probable future trajectories of 3D printing. Additionally, we take a retrospective look, examining the progressive evolution of this transformative technology.

Colonel James Allen Regenor had a distinguished career, flying tankers and transport aircraft for the U.S. Air Force before serving under President Bush and the National Security Council (NSC). After his time at the NSC, he took command of the 521st Air Mobility Group. He later joined MOOG in their Additive division. Currently, he is the CEO of VeriTX, a company focused on securing the digital supply chain for additive manufacturing and various other files. His career is filled with exciting stories, and he offers valuable insights into an often-overlooked aspect of additive technology.

After decades of engineering and leading teams at Jaguar Land Rover, Steve Cox made an unexpected career shift to focus on 3D printing education through his own company, Amfori. This transition has allowed Steve to delve deeply into the world of 3D printing. While he assists educators in adopting the technology, his primary focus is on providing training and consulting services for businesses, both large and small. With his forthright personality, Steve promises an episode that is not only educational but also highly entertaining.

Mitch Altman, a pioneer in the fields of field-programmable gate arrays and virtual reality, has long been a leading figure in the maker community. Not only did he help establish the Noisebridge hackerspace, but he’s also taught thousands how to solder while globe-trotting as an ambassador for makers. Additionally, Mitch created the TV-B-Gone universal remote, a device designed to turn off televisions. Far from a whimsical endeavor, his motivation for this invention is deeply personal. In this episode of the 3DPOD, our conversations with Mitch, touching on open hardware, maker spaces, and technology development, were incredibly enriching.

Douglas Krone co-founded Dynamism, a reseller specializing in a range of 3D printers, from desktop to industrial models, for the U.S. market. This successful enterprise has become a leader in the professional 3D printing segment. In this episode of the 3DPOD, Douglas shares insights, fortunate turns, and his vision for the company. However, his expertise doesn’t stop there. He also founded Brule, which is introducing 3D printing technology to Japan and Korea. As a result, Douglas offers valuable perspectives on the emerging markets in these countries.

Sarah Jordan, a seasoned expert in casting, forging, and metallurgy, is channeling her extensive knowledge into an innovative 3D printing technique with which she founded Skuld. Her startup’s specialization in lost foam casting has led it to pioneer a 3D-printed foam casting method. Despite Sarah’s characteristic humility, it is apparent that she and her team have constructed a sophisticated factory capable of producing low-cost metal parts. By streamlining the casting process, this new technique not only offers economic advantages but also accelerates time to market compared to conventional methods. While Skuld may not yet be a household name, its groundbreaking work has the potential to disrupt not just the world of 3D printing but also the broader manufacturing landscape.

Nicoline van Enter, a seasoned figure in the realms of footwear and trend forecasting, has taken her expertise to Footwearology, where she leads training and workshops for those eager to learn about 3D printing or 3D knitting shoes. Finding herself at the crossroads of the massive footwear industry and the emerging trend of 3D printing, she was able to share insights in a lively and informative conversation on the 3DPOD about the impact and future of 3D-printed footwear. A must-listen for anyone intrigued by shoes.

Kerry Stevenson was a CTO in the Insurance industry until he turned his focus to 3D printing and started a blog called Fabbaloo. Since 2007, Kerry has offered the industry his unique look at additive manufacturing. In this episode of the 3DPOD, he gives us a candid look at the industry over the time that he’s followed it. We discuss trends, developments, disappointments and breakthroughs in the industry over the years.

In this episode of the 3DPOD, we speak to Tyler LeBrun. Currently serving as Additive Manufacturing Lead at Sandia National Laboratories, LeBrun previously worked at Aerojet Rocketdyne and Blue Origin. In addition, he lends his expertise to the manufacturing non-profit SME with its efforts in standards. What follows is a conversation about standards, space, engineering and additive manufacturing that we think you’ll find fascinating.

In this episode of the 3DPOD, we once again welcomed Max Heres, who elaborated further on his large format material extrusion company, Loci Robotics. We delved deeper into the intricacies occurring within the nozzle during large format or desktop 3D printing. We explored the factors that influence part quality and extrusion, with Max providing insightful explanations about these factors and their interrelationships. But more critically, we examined how these systems operate and how, as a user or machine designer, one can modify these variables and influence their effects.

Trio Labs is quietly revolutionizing the field of small metal parts with its high-volume, accurate metal 3D printing technology. Since 2017, the company has been concentrating its efforts on medical devices. On this episode of the 3DPOD, we gain insights from Trio Labs’ founder, Adam Steege. We also have the opportunity to explore the medical 3D printing and development market with Scott Schiller, an HP veteran and the current CMO of Trio Labs. We dive into a conversation about the company’s market entry strategy, objectives, and future aspirations.

Found in 3D printers, busses, airplanes, cars and a lot of electronics worldwide, wire harnesses are often made by hand, a country or two over from where the end system is ultimately assembled. This arrangement not only makes their implementation slow and inefficient, but also leads to product delays. British startup Q5D has developed a manufacturing cell that uses 3D printing, pick and place, and more to manufacture these complex structures. In this episode of 3DPOD, co-host Max Bogue and I learn just how much potential there is for Q5D’s technology. For instance, did you know that every wire harness in every Toyota Camry includes the wiring for an electric sunroof, even though only very few of the vehicles actually include that option. Clearly, wire harnesses can be made more flexibly and efficiently.

In this episode of the 3DPOD, we talk to Gareth Neal, Business Development Manager EMEA + Israel for Xaar. The British firm manufactures inkjet printheads and Gareth wants you to build your next 3D printer with their heads. He works with customers to produce coating, bioprinting and 3D printing devices with inkjet. Long known as a color 3D printing technology, inkjet is now also being hyped because of its use binder jet. In our discussion with Gareth, we learn that there are more possibilities still in high-viscosity inkjet, electronics, and beyond.

Natalie Wadley started a 3D printing construction business with her husband. Rather than sell material or 3D printers ChangeMaker3D is an integrator that organizes, marshals technology, and builds parts. The couple has executed 3D printing projects for houses, water infrastructure, and train infrastructure projects. In this episode of the 3DPOD, we get a ground-floor view at the real possibilities and difficulties of 3D printing in construction.

Nick Pearce is a recruiter who helped start Alexander Daniels Global, a firm specialized in headhunting for the Additive Manufacturing industry. As the director of the company, Nick´s vantage point informs a discussion of job interviews, networking, salary trends, the talent pool for additive, job hopping, hiring, and much more. This is a great perspective for companies aiming to hire or employees that want to optimize their careers in 3D printing.

In this episode of the 3DPOD, we talk with Zach Detweiler, vice president of Technology at Velo3D (NYSE: VLD), about his past as a chemist and the path that took him to his current position. We also go through the complex systems that intertwine to form a metal powder bed fusion system, including the variables that need to be controlled and what must be done in order to achieve industrial manufacturing of 3D printed parts.

Mark Abshire has had a very long history in 3D printing. Beginning as a Rapid Prototyping manager at Texas Instruments, he was one of the first users of stereolithography in the world. He later on went to perform applications engineering at 3D Systems before joining Sony for its foray into 3D printing. Later, he worked for DSM Somos. Mark is a wealth of information on 3D printing and has a deep love for the Additive Manufacturing Users Group (AMUG). On this episode of the 3DPOD, he discusses why you should go to the annual AMUG Conference and why it is relevant. Mark also shares a just a piece of the many wonderful tales he has about a life in 3D printing.

Paul D’Urso is a pioneering surgeon and entrepreneur. As founder of Anatomics, he’s been an instrumental figure in developing 3D printed implants of all kinds. In this episode of the 3DPOD, Paul gives us a candid look at the opportunities, challenges and recent past of 3D printed implants. This is a great episode dealing with innovation, implants, medical 3D printing and more.

Previous guest Duann Scott is back to discuss some new ventures and projects he’s involved with, including MIT’s xPRO course on additive. What is covered, what do you learn, and for whom is the course? We also talk about 3MF, artificial intelligence, and lots of other subjects. An entertaining episode that you should enjoy as much as we did making it.

Today we interview Max Bogue, co-host of the 3DPOD. He tells us how he went from the genesis of the idea for a 3D printing pen to creating the product to founding the company 3Doodler. As major moments in his story, Max points to saying no to huge opportunities, having dogs in the office, and visiting factories. What follows is a great story and a lot of very practical advice, including good patent lawyers and the importance of different company structures , along with a lot more that will be helpful to entrepreneurs.

Chris Tuck is an entrepreneur and Nottingham University professor playing an outsized role in commercializing and researching new 3D printing technologies. He’s made a number of breakthroughs in binder jet, as well as founded Added Scientific and Reactive Fusion. While Added Scientific is a consultancy that can help you create your very own binder jet technology, material or production process, Reactive Fusion is a binder jet technology developed for polyurethane. That in itself is completely wild and could very well be a path to cost-effective, durable, and soft consumer goods with 3D printing. What we really liked about this conversation was the holistic way he has about refining technologies and making them production-ready.

Before starting Loci Robotics, Max Heres had a storied history beginning with the study of polymer physics before working as a graduate research assistant at Oak Ridge National Laboratory and going on to large-format 3D printing startup Local Motors. His deep experience in this technology led him to come up with a company that makes robotic arm-based polymer 3D printers. We end up taking a fascinating segue into the physics of what goes on when you 3D print. Max was able to explain some completely simple things that we knew and some others that we didn’t know very well. Really great episode.