NASA Update: Master Class, Alloys, AI & the Future Engineering Generations
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.
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Why Ursa Major is Betting Big on Additive Manufacturing
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 Manufacturing02:04 Early Career and First Additive Roles04:38 Joining Ursa Major and Initial Challenges10:11 Vertical Integration and Scaling Challenges20:14 Advanced Additive Strategies and Collaborations26:28 Automating Build Setups with Python26:58 Challenges in Hiring Additive Process Engineers28:06 Building a Passionate and Skilled Team29:30 Leveraging Local Talent and Resources31:17 Collaborating Across the Aerospace and Defense Industry32:50 URS's Product Portfolio and Additive Manufacturing35:34 Flexible Manufacturing for Solid Rocket Motors39:07 Future Developments in Additive Manufacturing41:35 The Importance of Material Development46:29 Scaling Operations and Advice for Newcomers
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What the Wholers Report & ASTM Reveal about the Industry's Future
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
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Additive Manufacturing, Then & Now: A Conversation with Alex Oster, Autodesk
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
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!
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