AM Radio

Postprocessing is a necessary part of the additive manufacturing (AM) workflow in almost every instance, because 3D printing alone rarely yields a finished part ready for use. Depending on the materials and processes they choose, AM adopters have to account for depowdering, curing, heat treat, cleaning, dyeing, tumbling, machining and many other post-print operations. Coupled with the high-mix, low-volume production typical in AM, such steps are difficult to automate or optimize — leading many companies to develop innovative and often secretive internal processes. In this episode of AM Radio, Stephanie Hendrixson, Peter Zelinski, Jessica Pompili and Jodee McElfresh share examples of how additive manufacturers solve their varied postprocessing challenges and seek to answer some of the questions around these critical steps. Thanks to listeners who sent questions, left comments or lent their expertise to this episode, including Matt Havekost, Rick Beddoe, Miguel Valenzuela, Konstantin Rybalcenko, Rey Chu, John…

A question from an audience member about competing production rates for a forged metal part that might be made through additive manufacturing instead got Pete Zelinski thinking about production rate in general, and what this rate does and does not tell us about productivity overall. Additive can win a production "race." An example involving a 1,000-piece production run of parts otherwise made through molding was documented by Formlabs (more info below). However, is a head-to-head comparison like this the measure by which additive must succeed? Pete explores this question. Find photos, related links and the transcript for this episode on AdditiveManufacturing.Media. Mentioned in this episode: From Formlabs, 3D printing vs. injection molding for a 1,000-piece run. Our report at Big Metal Additive on directed energy deposition for Navy projectiles. Subscribe to The BuildUp, our twice-weekly Additive Manufacturing newsletter.

Formnext 2024 lived up to its reputation as additive manufacturing's largest trade show, attracting more than 34,000 attendees to 54,000 m2 of exhibit space. It was also large in the sense of showcasing just how big 3D printing can go, with plenty of showpieces and demos running to illustrate the current scale of large-format additive manufacturing (LFAM) technology. But beneath the robotic arms and towering prints, there were also plenty of new machine introductions, software advances and application examples. Over the course of their time at the show, AM Radio cohosts Peter Zelinski and Stephanie Hendrixson noted more semiconductor applications than ever before, an increased use of tungsten, software developments aimed at solving AM's design bottleneck, various approaches to cutting cost per part, and indications that additive manufacturing has crossed various tipping points expanding where the production method makes sense, and is on trajectory to continue that advance. In this episode of the AM Radio…

Additive manufacturing and robots are parallel technologies, both digitally enabled tools for manufacturing that are advancing in adoption. But they also enable each other. 3D printing can provide the grippers, end effectors and other specialized tooling that robots require to serve production. And robots are driving AM forward as well. Collaborative robots or cobots are being used to tend 3D printer farms, sometimes mounted on autonomous guided vehicles (AGVs) for a fully mobile, as well as automated, solution. And robots are opening opportunities for larger and more complex part production, by providing the motion for a growing number of large format additive manufacturing (LFAM) systems. In this episode of AM Radio, Gardner Business Media Robots & Autonomy editor Julia Hider joins Stephanie Hendrixson and Pete Zelinski to discuss how AM and robots interact, and specific examples of this interaction. Find photos, video, related links and the transcript for this episode on AdditiveManufacturing.Media. This…

The 2024 edition of IMTS – The International Manufacturing Technology Show welcomed more than 89,000 attendees to Chicago last week. While only a portion of the show's 1,500 exhibitors were offering additive manufacturing equipment or services, AM nevertheless had a significant footprint at this show. Conversations with speakers, exhibitors and attendees revealed insights about where additive is finding traction now, and where it is heading next. In this episode of AM Radio, I talk with Pete Zelinski about equipment launches during the show, advances in usability and accessibility, AM's role in the casting supply chain, the increased presence of service providers, and how the next "phase" of AM will look different. Find photos, related links and the transcript for this episode on AdditiveManufacturing.Media. This episode is brought to you by Additive Manufacturing Media. Never miss a story. Mentioned in this episode: LinkedIn feeds: Stephanie | Pete Videos from the show: Robot Machining and Robot DED Video:…

Stephanie Hendrixson shares observations from her visit to learn more about two different manufacturing institutes under the umbrella of Carnegie Mellon University. First, she visited the lab facilities at Mill 19, a refurbished steel mill site, used by the Manufacturing Futures Institute. The MFI aims to accelerate the digital transformation of manufacturing, through work that includes things like robotics, digital twins and generative design as well as AM. She also learned about the Next Manufacturing Center, CMU's additive-focused research institute seeking to solve increasingly specific 3D printing problems— including how to model and avoid spatter in laser powder bed fusion. Find photos, related links and the transcript for this episode on AdditiveManufacturing.Media. This episode is brought to you by Additive Manufacturing Media. Never miss a story. Want to be the first to see the episodes of The Cool Parts Show we created with Carnegie Mellon? Sign up for our ALL ACCESS newsletter for fans of the…

In this follow-up to episode #51 of AM Radio, Dr. Tim Simpson joins Stephanie Hendrixson and Pete Zelinski in the studio to talk more about how NASA is implementing and shaping additive manufacturing. As part of an intergovernmental personnel act (IPA) assignment, Dr. Simpson has spent the last two years deployed within NASA helping to advance additive use cases and connect AM users within the organization. In this episode, he shares insights from this work including NASA's collaborative relationship with commercial space; its role in studying AM fundamentals and providing testing resources; missions currently using the technology; and where additive will enable NASA to go next. Find photos, related links and the transcript for this episode on AdditiveManufacturing.Media. This episode is brought to you by Additive Manufacturing Media. Never miss a story. Mentioned in this episode: Episode #51 (PART 1) The Cool Parts Show episodes featuring: "Evolved" bracket structures for the EXCITE mission, seen at Goddard…

Additive Manufacturing Media editors have had the chance to visit three different NASA facilities: the Goddard Space Flight Center, Jet Propulsion Laboratory and Marshall Space Flight Center. Pete Zelinski and Stephanie Hendrixson learned and reported on how 3D printing is being used to fulfill NASA missions through parts like a generatively designed bracket, lightweight titanium lattices and a multimaterial thrust chamber made with two different processes. But where do these parts fit within NASA's broader mission, and what is the role of additive manufacturing at NASA? In this episode, part 1 of a 2-part series, Pete and Stephanie discuss what it's like to visit NASA and the observations they gleaned from being on site. (Make sure to subscribe and join us for Part 2, featuring AM Radio cohost and NASA system design innovator Dr. Tim Simpson.) Find photos, related links and the transcript for this episode on AdditiveManufacturing.Media. This episode is brought to you by THE BUILDUP. Mentioned in this…

When we first covered Model No. in 2020, the company was manufacturing furniture on its own large-format 3D printers, built to designs directly manipulated by customers through parametric options available on its website. Four years later, production looks a bit different. Gone is the user-facing design tool, as the company has discovered that conversation with customers is the more effective way to arrive at the right designs for its clients. More colors and materials are offered today, in part because of a circular economy-focused project that Model No. completed with several partners. And there's one important change to how furniture is made--listen to the episode to learn how (and why) the company's 3D printing capacity has evolved in the last few years. Find photos, related links and the transcript for this episode on AdditiveManufacturing.Media. This episode is brought to you by Additive Manufacturing Media. Never miss a story. Mentioned in this episode: The 2024 update article about Model No.…

We are trying something new on the podcast! Whenever one of us on Additive Manufacturing Media pays a visit to a manufacturer for the first time, we want to talk about the trip as soon as we return. Why keep this recap to ourselves? In this episode of AM Radio, here is Stephanie Hendrixson getting the full download just after I paid a visit to Innovative 3D Manufacturing in Franklin, Indiana. Innovative does contract production using 12 laser powder bed fusion machines, all from Renishaw. Just part of what struck me is this company's connection to foundry work — not just in terms of process, such as workholding technique, but also in terms of business opportunity, because Innovative is getting work due to foundry leadtime challenges. Listen to our conversation above, or on your favorite podcast app. And for even more on Innovative, read the article I wrote, which is linked below. - Peter Zelinski, editor-in-chief, Additive Manufacturing Mentioned in this episode: Pete's companion article on Innovative 3D…

What is qualification, and what does it entail for additive manufacturing applications? In this episode of AM Radio, Dr. Tim Simpson joins Additive Manufacturing Media editors Pete Zelinski and Stephanie Hendrixson to talk about various issues around qualification in AM, including: the difference between qualification and certification; the expense of qualification activities; how standards are developed; and the opportunities additive can realize with qualified procedures. Find related links and the transcript for this episode on AdditiveManufacturing.Media. This episode is brought to you by The Cool Parts Show. Mentioned in this episode: How RP+M manufactures aerospace parts for major OEMs and helped to create NCAMP Document 89085 NASA STD 6030 American Welding Society's AWS D20 ASTM standards on additive manufacturing SAE's AMS standards for additive manufacturing FDA's Technical Considerations for Additive Manufactured Medical Devices Würth Additive Group's work to develop digital inventory solutions…

In the last episode of AM Radio for 2023, hosts Pete Zelinski, Stephanie Hendrixson and Fiona Lawler look back on Additive Manufacturing Media's top 10 stories by pageviews for the year. The list reveals some interesting trends including the ramp up in additive manufacturing "factories," additive adoption that necessitates more sophisticated downstream processing, and a heavy emphasis on metal 3D printing. In the second half of the show, the hosts share their favorite stories, regardless of ranking, written by someone else. Find photos, related links and the transcript for this episode here. This episode is brought to you by Additive Manufacturing Media. Never miss a story. Mentioned in this episode: Top 10 stories by pageviews for 2023 AM Factory issue of Additive Manufacturing Magazine United Performance Metals Is the One-Stop Build Plate Shop for Production AM 3D Printing Project to Advance Medical Device Customization New Zeda Additive Manufacturing Factory in Ohio Will Serve Medical, Military and…

The world's largest trade show for additive manufacturing technology featured more than 800 exhibitors across the entire AM value chain. Additive Manufacturing editors Peter Zelinski and Stephanie Hendrixson discuss what they learned and discovered at the event in this episode, including the rise of copper, the introduction of new processes for 3D printing in metals, equipment upgrades that don't rely on hardware, reduced barriers to entry for AM and much more. Find photos, related links and the transcript for this episode on AdditiveManufacturing.Media. This episode is brought to you by THE BUILDUP. Mentioned in this episode: Formnext Coverage of the 2022 show Reinforce3D's postprocess reinforcing technique Horizon Microtechnologies' functional coatings Machine Improvements That Don't Rely on Hardware Renishaw's Tempus system for simultaneous laser scanning and recoating EOS's Smart Fusion for controlling the melt pool temperature AI Build's toolpath and slicing software for robot-based systems Dyndrite's…

Additive manufacturing "factories" and other facilities that have been built from the ground up to serve this process are becoming increasingly common, but a purpose-built space is not a necessity for successfully applying AM. Stephanie Hendrixson and Fiona Lawler discuss Fiona's recent trip to visit a newly established Protolabs facility dedicated to laser powder bed fusion, and swap stories of other AM spaces--from a 3D printer tucked under the stairs to a rented office space all the way to buildings acquired or built just for production additive manufacturing. This episode is brought to you by AM Media. Subscribe and learn more at www.additivemanufacturing.media. See photos and find the transcript for this episode at on our website. Mentioned in this episode: Fiona Lawler's article on her visit to Protolabs' new Raleigh, North Carolina, metal additive manufacturing facility Slice Mfg, medical implant manufacturer in Akron, Ohio OMG Additive, Cincinnati-based startup founded by JP Kinerk CATCH, the…

Sporting goods, tooling, integration with conventional processes, multi materials — in this episode of AM Radio, Jodee McElfresh and Pete Zelinski discuss the topics that have been popular on the Additive Manufacturing Media website and social media recently. Mentioned in Episode: Snarr3D's 3D printed golf putter shafts article and LinkedIn post ActivArmor's 3D printed casts The Cool Parts Show episode and LinkedIn post Jodee's post with the EOS 3D printed top Pete's post about the America Makes MMX event InssTek's rocket nozzle made through DED Three major phases in the advance of additive manufacturing Airtech's 3D printed automotive tool Humtown's sand 3D printed dinosaur egg video and article Bauer Hockey's personalized equipment RePliForm's electroplating of polymer 3D printed parts article and LinkedIn post Subscribe to The BuildUp, our twice weekly newsletter about all things additive.

Formnext Forum Austin, the first Formnext event to be held in the United States, concluded August 30 after two full days of conference programming dedicated to industrial additive manufacturing. The event is jointly organized by Mesago Messe Frankfurt, AMT—The Association For Manufacturing Technology, and Gardner Business Media, the publisher of Additive Manufacturing Media. Along with sessions on additive end markets, production applications, AM technology and design for additive manufacturing (DFAM), Formnext Forum included a lively expo featuring nearly 80 exhibitors plus The Cool Parts Showcase. Attendees also had access to several facility tours and networking opportunities. The event drew more than 900 attendees, including the editors of Additive Manufacturing. Pete Zelinski, Fiona Lawler and Stephanie Hendrixson recorded this conversation for AM Radio shortly after the event. Find photos and the transcript of this episode in this blog post. This episode is brought to you by The Cool Parts Show.…

Succeeding with additive manufacturing from a technical perspective has to be followed by succeeding with AM from an organizational perspective. Additive is a different production process entailing different enterprise, workflow and costing considerations, not to mention different personnel, communication and cultural considerations as well. Dr. Tim Simpson and Peter Zelinski talk about all of this: how to organize for success when additive manufacturing is the production process. This episode of AM Radio is brought to you by Formnext Forum Austin. Mentioned in this episode: Additive manufacturing provider Keselowski Advanced Manufacturing New major Zeda additive manufacturing facility opening in Ohio Our coverage of the new AM factories VulcanForms' approach to digital production CIMP-3D, the facility Tim Simpson co-leads at Penn State Collins Aerospace's use of AM to protect intellectual property Episode of AM Radio all about bridge production Eaton AM facility, including its strategy for adapting to…

As a "born digital" technology, additive manufacturing intrinsically relies on data, more so than any other manufacturing process. That data reliance potentially exposes AM users to data security and cybersecurity issues; efforts are underway to help these users protect designs, print parameters, machines and even 3D printed parts. But beyond the dark side of data, figuring out secure ways of storing and sharing data also opens the door to more freely distributing manufacturing, sharing material and print profiles, and flexible, secure supply chains. Stephanie Hendrixson and Dr. Tim Simpson discuss all things AM data on AM Radio. This episode of AM Radio is brought to you by Formnext Forum: Austin. Mentioned in this episode: Episode 37 on sustainability CyManII and its efforts to protect an additive manufacturing company NIST introduces a new "dictionary" for data definitions in AM VeriTX's Fortis platform for data assurance Senvol industrial AM machine and material database TRACEam program from Mike Vasquez…

Additive manufacturing is a dynamic space for various reasons: The technology is advancing and application possibilities are still being developed, and as a direct consequence, the landscape of AM companies is subject to change due to investor moves; mergers and acquisitions; and startups emerging from "stealth mode." On this podcast, and in related reporting for Additive Manufacturing Media, we serve manufacturers by covering AM technology and applications — the corporate and financial moves are not the focus. And yet, one realm affects the other. The company moves shape what we cover and affect the choices of manufacturers as they aim to proceed with the technology. In this episode of AM Radio, Peter Zelinski and Stephanie Hendrixson talk about this. They discuss how the corporate and financial developments among AM companies play out for AM users, and where the dynamism of the additive space is likely to lead in the future. This episode of AM Radio is brought to you by Formnext Forum: Austin. Mentioned in…

Additive manufacturing offers significant promise for strengthening and simplifying manufacturing supply chains. We glimpsed this during the pandemic, when 3D printers provided a quick response for needed medical components for uses such as ventilators and personal protective equipment. What are the ways AM can answer supply chain problems longer term, and how close are we to realizing this promise? In this episode of the AM Radio podcast, I am joined by Penn State's Dr. Tim Simpson as we discuss additive manufacturing as a logistics solution, 3D printing for faster lead time relative to casting and forging, AM for MRO and sustainment needs, and other aspects of additive as a supply chain solution. Mentioned in this episode: Dr. Tim Simpson's additive manufacturing research organization at Penn State University Additive manufacturing for personal protective equipment (PPE) during the pandemic Sand 3D printing as a way to improve metal casting 3D printed TPU seals for GM's Chevy Tahoe AMNOW digital additive…

At the 2023 edition of RAPID + TCT held in Chicago, Additive Manufacturing Media editors noticed evidence of AM's maturation both in terms of technical capability and utility for end-use applications. Stephanie Hendrixson, Peter Zelinski and Fiona Lawler discuss themes discovered at the event, including more precise DED, new tools for process monitoring, more sophisticated understanding of AM and sustainability, AM winning on cost and much more. Find photos and video from the show in this blog post on our website. This episode is brought to you by Formnext Forum: Austin. Mentioned in this episode: RAPID + TCT Fiona Lawler's work for Additive Manufacturing Media Sustainability Caracol robot-based DED used to 3D print wind turbines from old wind turbines Thermwood's LSAM 510 3D printer used to print chairs live at the show SABIC's LNP ELCRIN WF006NiQ resin made with post-consumer PET An impeller 3D printed with Uniformity Labs' Ti64 Grade 23, with scan time reduced by 1.5× Uniformity labs: aluminum powder for…

Is additive manufacturing inherently more sustainable than conventional manufacturing methods? Stephanie Hendrixson and Dr. Tim Simpson wade into the various factors that must be considered to make this assessment; dive into some of the research happening in industry and academia on the subject; and discuss why sustainability is such a tricky problem in AM. This episode of AM Radio is brought to you by Formnext Forum: Austin. Mentioned in this episode: "Plastics: Knowledge and Information Taking Shape," the art exhibit at Penn State University's Pattee Library in 2017 3D print recycling program at PSU's Maker Commons How MolyWorks atomizes metal powders in the footprint of a shipping container 6K Additive's lifecycle analysis on nickel produced through its UniMelt process Results from the Additive Manufacturing Green Trade Association (AMGTA) lifecycle assessment of an aerospace bracket Review paper with Kate Whitefoot on the potential environmental and economic impacts of AM Tom Lauerman's 3D printed clay…

With the arrival of resources such as ChatGPT and Dall-E, artificial intelligence (AI) is a widespread topic of discussion. But AI has been aiding additive manufacturing for years, to the extent that the applications are coming to seem pervasive. Stephanie Hendrixson and Peter Zelinski talk about the link between AI and AM, both as we see it today and as we expect to see it in the future. What AI and AM have in common is frictionlessness — in terms of offering instruction, as ChatGPT shows, and in the ease of starting production without need for hard tooling that 3D printing makes possible. What will we see as these two advancing technologies increasingly come together? Mentioned in this episode: Additive Manufacturing magazine issues on machine learning and artificial intelligence NNAISENSE defect prediction via machine learning from heat maps Argonne National Laboratory work correlating AM heat maps to X-rays of metal parts Castor AI analysis of parts suitable for 3D printing Army call for research into…

A sign of the advancing understanding of additive manufacturing: Many of the previous misperceptions have gone away. Or they have at least dramatically declined. Few in manufacturing today believe 3D printing is as simple as "hit print," and most understand that the design of the part determines how well it can take advantage of AM. However, there are still pervasive misperceptions about AM among the manufacturers today who are just beginning to explore it. Tim Simpson and Peter Zelinski talk about some of the false ideas about additive manufacturing that are in the air and current now. Part of the challenge is simply that AM technology is still changing rapidly; assumptions become invalidated quickly. Tim ends up talking about the pace of this change in additive and what is setting that pace. Mentioned in this episode: Penn State's CIMP-3D, the additive manufacturing research facility Tim co-leads Additive manufacturing's increasing presence at IMTS, the International Manufacturing Technology Show Stryker…

Additive manufacturing (AM) tends to see popular media coverage when a consumer good is 3D printed. 3D printed houses and fashion grace headlines at the moment. On social media, however, additive manufacturing is a daily topic of conversation for users, students and entrepreneurs. As digital editor for Additive Manufacturing Media, I have the pleasure of observing and engaging in some of those conversations. On this episode of the AM Radio podcast, Peter Zelinski and I review eight AM-related social media posts that caught my eye in recent weeks. Among the topics we discuss are machine modifications, a debatable assumption about large-format additive manufacturing and the AM fan-favorite, or maybe anti-fan favorite: AM's cost effectiveness. Thanks for listening. Mentioned in this episode The posts from social media: Our post about the SABIC regrind study Stephanie's post about the SABIC study Luai Kurdi's extrusion robot on a pedestal Catalysis Additive Tooling's thermoforming tool Enrico Gallino's display…

Bringing additive manufacturing to scale production also means scaling the workforce trained to design, manage and carry out that production. While some fundamentals stay the same across material and process, learning the intricacies of specific applications and industries takes time. What is the role of the university in preparing the next generation of additive manufacturers? What should industry expect in new hires, and how can companies upskill their existing workforce? And what are the "soft skills" or personality traits that make for a successful user of additive manufacturing? In this episode of the AM Radio podcast, I discuss training and education options for additive with Dr. Tim Simpson, professor of mechanical and industrial engineering at Penn State University and contributor to Additive Manufacturing Media (among his various other roles). This episode is the first of a series that will feature Simpson as cohost. This episode of AM Radio is brought to you by PTXPO. Mentioned in this episode:…

3D printing for repair and replacement is an underappreciated but potentially very valuable application for this technology. The ability to add material only where necessary and to do so in an automated fashion allows worn surfaces to be rebuilt with less human labor, keeping items such as aircraft blades in service for longer. Additive manufacturing offers an avenue for manufacturing parts no longer in inventory or production, by skipping over tooling to arrive more quickly (and often, more affordably) at the needed component — it be a brush mat, bearing housing, mixer blade, clamp or tractor tread. But a 3D printed replacement part is rarely a 1-to-1 swap; changing to this production method almost always introduces additional benefits. In this episode of AM Radio, Pete Zelinski and I discuss these examples and more, plus why a 3D printed replacement is almost always an upgrade. This episode of the AM Radio podcast is brought to you by PTXPO. Mentioned in this episode: Acme Manufacturing's automated…

The most-viewed stories on AdditiveManufacturing.Media this year illustrate some of the trends in industrial 3D printing, including its increasing adoption for spare and replacement parts; increased applications for electric motors; and a maturing user base. Peter Zelinski, Stephanie Hendrixson and Jodee McElfresh take a look back at the top 10 articles and videos from 2022. This episode is brought to you by The Cool Parts Show. Mentioned in this episode: 500-Pound Replacement Part 3D Printed by Robot: The Cool Parts Show #50 Can Metal Parts Be Replaced With 3D Printed Composites? How Siemens Energy Applies Additive Manufacturing for Power Generation and More 3D Printing Rotors for Electric Motors (Video) Custom Canine Wheelchair From Carbon Fiber-Reinforced PP: The Cool Parts Show #44 The First Choice Was Right: How RP+M Succeeded With Production FDM For Polymer 3D Printers, Metal Parts Are Now Within Reach 10 Ways Additive Manufacturing Reshapes a Production Facility (Forget What You Know About Factories)…

Additive manufacturing's largest trade show, Formnext, returned to its pre-pandemic strength in 2022. In this episode, Peter Zelinski describes trends from the show floor (including 3D printing with ceramics, anticipating robot automation, and a pivot away from support structures) while Stephanie Hendrixson shares observations found in social media. This episode is brought to you by PTXPO. Mentioned in this episode: Pete's post-show report on Formnext 2022 Videos filmed at the show: Wasp 3D printing with clay An example of a part made with EOS's Autodesk plugin for optimizing supports Metrom's high-speed parallel kinematic 3D printing platform How Duplex 3D prints a kayak paddle from two directions at once Advances in binder jetting from GE Additive Rivelin and robots for machining metal 3D printed parts Nexa3D ceramic composite resin Nanoe's Zetamix RF material Our episode of The Cool Parts Show featuring Lithoz 3D printed ceramic Grob Liquid Metal Printing system KraussMaffei's powerPrint and…

Additive Manufacturing Media digital associate editor Jodee McElfresh joins the podcast for this episode inspired by trends spotted on social media. She and Stephanie Hendrixson discuss additive manufacturing superlatives and the value of the "boring" part, plus how individuals and companies can make the pivot into AM. Spoiler: Waiting for the next generation won't be enough; consider workforce development from the inside. This episode is brought to you by the The Cool Parts Show. Mentioned in this episode: Our episode of The Cool Parts Show on a 3D printed bracket that replaces a machined metal version More stories of #brackets Las Vegas Raiders monument Julia Hider's story on how Werco Manufacturing uses 3D printed composites to make parts for aircraft maintenance training Our resource on pursuing a career in additive manufacturing Iten Industries' Imagineering Center and applications for polymer 3D printing How Flex uses disparate additive manufacturing centers to advance AM's use Micro architected metals…

Additive manufacturing (AM) has overcome many obstacles to become an accepted production method in spaces where it makes sense. But the work is not done yet. Manufacturers who are now applying 3D printing for ongoing production at scale are discovering how issues that seemed small at first are now growing into problems that need solutions. In this episode, hosts Stephanie Hendrixson and Peter Zelinski discuss six of these challenges. Want to tell us yours? Email amradio@additivemanufacturing.media and we might feature your comment in a future episode. This episode is brought to you by The Cool Parts Show. Mentioned in this episode: How scaling into production revealed sustainability challenges at Sintavia More on the method for passivating condensate developed by Sintavia, KBM and AMGTA Inside the GKN Additive production facility in Auburn Hills, Michigan Additive Industries' Powder Load Tool Single build with over 2,000 parts on Nexa3D photopolymer machine AM WTF: Why the Failure? video series with Dr. Tim…

Additive manufacturing is changing the possibilities for working with ceramics. Julia Hider and Peter Zelinski take stock of this, discussing various 3D printing processes making use of ceramic material and various applications benefiting from this. This leads to a conversation about the cases where additive is providing an alternative to casting. This episode brought to you by The Cool Parts Show. Mentioned on this episode: Deka Research 3D printed component in Mar M 247 Chaos Ultra-Car ceramic piston made with XJet material jetting Hyperion 3D printing of tungsten carbide via binder jetting GE Additive/Kennametal partnership around binder jetting of tungsten carbide Ultra Safe Nuclear Corporation and silicon carbide 3D printing for micro reactors 3D printing in clay by MadeXBinary 3D printed ceramic implant able to substitute for bone Aristo Cast ceramic forms used to make complex metal castings Alloy Enterprises and sheet lamination of aluminum Eaton's conversation of cast parts to AM

Pete Zelinski, Stephanie Hendrixson and Julia Hider recap additive manufacturing technology on display and other discoveries at IMTS--The International Manufacturing Technology Show in a live taping of AM Radio recorded from the AM4U stage at the show. Then, our hosts share insights from this year's co-located Additive Manufacturing Conference, which next year will transform into the Formnext Forum. This episode is brought to you by the The Cool Parts Show. Mentioned in this episode: IMTS—The International Manufacturing Technology Show Additive Manufacturing Conference Reporting on medical manufacturer RMS Our previous conversation on Formnext USA and the Formnext Forum

In additive manufacturing, design and production must inform each other — but do they need to live under the same roof or the same ownership? In this episode, Stephanie Hendrixson and Julia Hider consider business models that separate design from production, and in some cases provide the consumer substantial agency in the manufacturing process. Then, they discuss Artemis I and the various ways 3D printing is enabling or will advance space exploration. This episode is brought to you by the Additive Manufacturing Conference at IMTS. Mentioned in this episode: Julia's 3D printed hippo phone stand Spokbee's platform which allows for designers to sell customizable products that are 3D printed on demand Angled, another sales platform for designers that also provides production services via Slant3D printer farms Gantri, a lighting-focused sales platform The Future of Jewelry, which allows consumers an even larger role in the design of custom signet rings Maxwell June, the company founded and run by Rob Glenn based…

Cohosts of the video series and AM Radio Pete Zelinski and Stephanie Hendrixson reflect on three years and 50 episodes of The Cool Parts Show and what it means. Then, Pete, Stephanie and videographer Austin Grogan share their favorite episodes. This episode is brought to you by the Additive Manufacturing Conference at IMTS. Mentioned in this episode: The Cool Parts Show Our 50th episode on Lincoln Electric's mixer bearing housing Pete's favorite episode, on a vacuum accessory made by Dustless that was reshored thanks to 3D printing The Cool Pen Show bonus episode Stephanie's favorite episode, on a custom helmet for jiu-jitsu enthusiast Sarah Piersanti Austin's favorite episode, on the hull of an autonomous underwater vehicle (AUV) Stephanie's BAAM elevator ride

Manufacturers of electric vehicles (EVs) seem to be adopting additive manufacturing (AM) more readily into production than the conventional automotive industry and other transportation segments have. This adoption is in part because of the functional and geometric possibilities that additive brings, but it is also because EVs are being made in lower quantities and represent new product platforms without existing supply chains, tooling and processes to contend with. In this episode of the AM Radio podcast, Julia Hider and I discuss various ways that AM is and could be used to advance the future of transportation based on electric vehicles. This episode of the AM Radio podcast is brought to you by The Additive Manufacturing Conference at IMTS. Mentioned in this episode: AM for Electric Vehicles microsite (gbm.media/AM4EV) Ways additive is being used for EVs The GM seat bracket and what it says about the company's electric future Topology optimized components 3D printed for a car raced in the 2021 Dakar Rally…

Headed to IMTS--The International Manufacturing Technology Show, and curious about the additive manufacturing value there? Peter Zelinski and Julia Hider share insights about the show including the difference between two major AM events, what to expect on the AM4U stage, and general tips for surviving and thriving at the tradeshow. IMTS takes place in Chicago, September 12-17. This episode of AM Radio is brought to you by The Cool Parts Show. IMTS AMT—The Association for Manufacturing Technology Exhibitors at the IMTS Additive Manufacturing Pavilion Stratasys's Acquisition of Origin Nexa3D The Additive Manufacturing Conference at IMTS Tim Simpson's Column CIMP-3D The Additive Manufacturing for Job Shops Workshop Previous Episode of AM Radio with Discussion of Project DIAMOnD Previous Episode of AM Radio that Covers Formnext USA Five Tips to Prepare for IMTS IMTS MyShow Planner

Additive manufacturing contains more than 3D printing, but even this term carries multiple meanings. 3D printing might mean extruding plastic, or depositing binder into metal, or melting material with lasers, or any number of other things. In this episode, Stephanie Hendrixson and Peter Zelinski try to stump each other with some unusual 3D printing processes and consider whether the "Seven Families of Additive Manufacturing Technologies" are still relevant 10 years after they were created. This episode is brought to you by the Additive Manufacturing Conference at IMTS. Mentioned in this episode: Multi Jet Fusion (MJF) 101 Meld Manufacturing's solid-state process based on friction stir welding Grid Logic's multimaterial powder bed technology Fabrisonic's Ultrasonic Additive Manufacturing and application examples More on Massivit's Gel Dispensing Printing and how it can be applied for Cast In Motion, a way of quickly producing tooling for composites Moldjet process, as described in a video from Tritone A…

Modern Machine Shop senior editor Matt Danford joins Julia Hider to discuss five trends in digital manufacturing that are playing out for both machining and 3D printing. This episode is brought to you by the Additive Manufacturing Conference at IMTS. Mentioned in this episode: Data Matters, Matt Danford's Modern Machine Shop column covering Industry 4.0 in machining Matt's column about Five 3D Printing Trends Mirrored in Machining HP's Digital Manufacturing Trends Report Article about micro mold shop Accumold's use of micro 3D printing for prototyping Advanced Precision Engineering, which uses a Markforged X7 desktop 3D printer to make custom robot grippers Podcast that discusses how Savage Automation uses 3D printing to make custom end of arm tooling for automation injection molding RAPID + TCT 2022 recap, with mention of the theme of collaboration, including Stratasys announcing the availability of third-party materials How machine monitoring platform MachineMetrics is gathering and using data from FANUC…

The conflict in Ukraine has intersections with the world of additive manufacturing. Hosts Stephanie Hendrixson, Peter Zelinski and Julia Hider discuss ways that 3D printing is bringing aid; realities of distributed manufacturing; and the effects of the war on one additive manufacturing business with operations in Ukraine. This episode is brought to you by the Additive Manufacturing Conference at IMTS. Mentioned in this episode: Project DIAMOnD Tucker Induction Systems, manufacturer and Project DIAMOnD node IQ Manufacturing, another Project DIAMOnD participant MarkForged Dinara Kasko on Instagram Ultimaker Extrusion in Motion ADAM Bioprinting and its entry in The Cool Parts Showcase: 3D printed bone Past episode on blockchain and AM Together We Are Strong Tech Against Tanks United 24 Mint for Ukraine

Editors Peter Zelinski, Stephanie Hendrixson and Julia Hider discuss discoveries and observations about 3D printing materials, processes, applications and scale from RAPID + TCT 2022, held in Detroit, May 16-19. This episode is brought to you by the Additive Manufacturing Conference at IMTS. Mentioned in this episode: RAPID+TCT Slideshow and blog post about the 2022 event RAPID 2021 recap GKN Additive Jabil's PK5000, a possible alternative to PA12 Machine builder and material supplier EOS Carbon self-extinguishing resin Another right-sized application for Braskem's polypropylene Stratasys materials collaborations with Kimya, Covestro and Mechnano, to name a few GE Additive and Kennametal collaboration on binder jet for tungsten carbide Materialise CO-AM platform for serial production Inkbit coverage Quantica, developer of an 3D printing jetting head Ceramic piston created by XJet AM-Flow's automated sorting system on display C1 system from AM Solutions for automated support removal from photopolymer prints…

Additive manufacturing is creating new opportunities for fiber-reinforced polymer composite materials. This has implications for the promise of AM and implications for the composites industry. In this episode, Peter Zelinski of Additive Manufacturing Media is joined by Jeff Sloan of sister brand CompositesWorld. They talk about composites replacing metal, large-format 3D printing for tooling, and other aspects of the overlap between these two worlds. Also, what does the acceptance and adoption of composites into part production, and the way this played out in previous decades, signal about the way ahead for an even newer disruptive technology, additive manufacturing? This episode is brought to you by the Additive Manufacturing Conference at IMTS. Mentioned in this episode: CompositesWorld 3D printing changing composites manufacturing: a Q&A with Jeff Sloan Composites replacing metal: an example Aerospace applications for 3D printed composites on a previous episode of AM Radio Large-format composites 3D…

Julia Hider shares 3D printing for production and various kinds of tooling spotted at the first-ever Plastics Technology Expo. Then, she and Pete Zelinski discuss new methods of 3D printing with polymers that deliver greater freedoms in terms of layer width, layer height, material viscosity and more. This episode is brought to you by the Additive Manufacturing Conference at IMTS. The call for papers is open through April 29, 2022. The Graduate plastics clip PTXPO AM 101: Multi Jet Fusion Another example of 3D printed plastics replacing metal Mantle's technology for 3D printed injection mold tooling Medical tweezers case study Xact Metal What is laser powder bed fusion? Fortify Ceramic fiber filled DLP 3D printed Innovent ejector pins from Next Chapter Manufacturing Video of the demo from Next Chapter Manufacturing's booth 3D printed porous copper filter 3D printed cutting tools 3D printed end of arm tooling 3D printed end of arm tooling section compared to traditional EOAT Where to find pictures and videos…

Can 3D printed polymers reinforced with chopped or continuous fibers be a suitable replacement for metal parts? In this episode, Julia Hider and Stephanie Hendrixson discuss at least three scenarios where this is taking place--and two of them happen to involve training devices related to aerospace. (Possibly a precursor to printed composites replacing metals on flight-worthy aircraft?) Then, our hosts dive into blockchain and its usefulness for protecting and distributing 3D printable files. This episode is brought to you by CompositesWorld. Mentioned in this episode: How Werco replaces metal aircraft components with 3D printed composites. A flight simulator body 3D printed with chopped carbon fiber-reinforced ABS on The Cool Parts Show Our previous episode of AM Radio on finishing of 3D printed parts with Scott Francis of Products Finishing The Cool Parts Show episode that put a 3D printed composite bracket up against its machined steel counterpart A characterization of blockchain technology by Modern…

3D printing is valuable as a means of bridge production—that is, manufacturing that is less than scale production, and likely temporary, but nonetheless filling a production need. Sometimes it comes between prototyping and serial production, or to cover a supply chain gap. Pete Zelinski and Stephanie Hendrixson discuss several examples where manufacturers are performing 3D printed bridge production to great advantage, as well as the cases where it makes sense to fully embrace AM for production instead. This episode is brought to you by PTXPO. Mentioned in this episode: Our 2018 story on Resolution Medical Subscribe to our newsletter here to receive the 2022 Resolution Medical update and our article on Smith Metal Products when they are published Tangible Solutions, an Ohio manufacturer of spine implants through 3D printing 3D printed foam pads for Wilson baseball mitts Adam Clark on stage at the 2017 Additive Manufacturing Conference (Be there for the next quotable moment at our 2022 event in September) The…

Additive manufacturing makes it possible to begin to make a new product cost-effectively at small scales through 3D printing, and both change the product design and scale up its production in response to market acceptance. This means inventors of new products can be their own manufacturers, and it's why inventors producing their own product is becoming a new category of manufacturer. Julia Hider recently visited an example: Maxwell June, maker of a new razor system for shaving. She and Peter Zelinski discuss what she found, and the reasons why additive manufacturing expands the possibilities for inventors. This episode is brought to you by PTXPO. Mentioned in this episode: Maxwell June The "mold moment" and AM's paths to production The Dustram and Jack King, its inventor, on The Cool Parts Show The Periscope phone case Ultimaker 2+, one of the machines used at Maxwell June Creality Ender-3 V2, the newer printers at Maxwell June More on extrusion 3D printing (FDM/FFF) More on vat photopolymerization…

A 3D printed part is rarely complete straight off the printer, and many additive manufacturers are accustomed to performing some level of cleaning and surface finishing. But postprocessing need not stop there. Electroplating, powder coating, anodizing and other processes can add improve the appearance, provide greater resistance and add functionality to 3D printed parts. On this episode of AM Radio, host Stephanie Hendrixson welcomes the show's first guest expert: Scott Francis, editor in chief of Products Finishing (a sister brand to Additive Manufacturing, published by Gardner Business Media). Mentioned in this episode: Products Finishing CompositesWorld Macaw with a 3D printed and anodized titanium beak Products Finishing Top Shops program REM Surface Finishing Faraday Technology Axalta Mobility Coatings

Additive Manufacturing Media, the brand behind AM Radio, is celebrating its 10-year anniversary in 2022. In this episode, Stephanie Hendrixson and Pete Zelinski take a look back at the last decade in 3D printing and additive manufacturing and then offer 6 predictions for the next ten years in AM. This episode is brought to you by PTXPO. Mentioned in this episode: Past issues in our digital archive The Additive Manufacturing Conference Our latest update on Linear AMS, including links to past stories 2015 story with Dr. Tim Simpson of Penn State University Deka Research and Development's work with Mar-M 247, a nickel-based alloy Lockheed Martin's work to 3D print satellite parts Tilt Hydrometer's use of 3D printing for a critical component of their device for beer monitoring A look at the lattice hidden inside Hilos' 3D printed shoe platform Cobra Golf putter with a lattice design IKEA's Flamträd 3D printed home décor line The Cool Parts Show episode on 3D printed magnets The Cool Parts Show on a carbon…

SHOW NOTES Additive manufacturing is realizing new possibilities for components at the extremes of size range. In this episode, Peter Zelinski and Julia Hider discuss micro 3D printing via DLP as well as large scale 3D printing enabled by robots, FDM, wire arc additive manufacturing (WAAM) and more. This episode is brought to you by PTXPO. Mentioned in this episode: Nano Dimension's Fabrica 2.0 (after this article was written, Nanofabrica was acquired by Nano Dimension, and the Tera 250 was renamed the Fabrica 2.0) Micro 3D printed electrical connectors from Boston Micro Fabrication Micro 3D printed eye stents for glaucoma surgery by Boston Micro Fabrication Micro injection mold shop Accumold's use of the Fabrica 2.0 Wire-arc additive manufacturing at Lincoln Electric Additive Solutions Additive Engineering Solutions using a BAAM machine from Cincinnati Incorporated for tooling Autonomous underwater vehicle hull sections 3D printed by Additive Engineering Solutions using BAAM Flight simulator cockpit 3D…

Julia Hider and Stephanie Hendrixson discuss the benefits and use cases for 3D printed lattices as a replacement for conventional foam materials. Then, they count down Additive Manufacturing's top 10 stories from 2021. This episode is brought to you by PTXPO. Mentioned in this episode: Rawlings' REV1X baseball glove featuring 3D printed inserts Carbon's Design Engine for lattice generation HEXR, manufacturer of custom bike helmets Hilos recyclable heels on The Cool Parts Show Aetrex 3D printed insoles on The Cool Parts Show Lubrizol and Colorfabb's VarioShore TPU foaming filament CNC Kitchen's video on VarioShore TPU Additive Manufacturing Media's Top 10 Stories from 2021