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37 minutes | Oct 13, 2021
Additive Manufacturing (AM) Polymer Materials Offer New Opportunities
The first rule of 3D printed polymers is the need to rethink applications at the specification level. Part specifications and properties can be improved upon dramatically with additive manufacturing. If you remain focused on legacy materials, specs, and processes you may miss out on the best opportunities to innovate. Host Fabian Alefeld speaks with Dr. Cary Baur, Senior Manager Polymer Technology of EOS, about the best ways to approach innovation with 3D printed polymers, how to separate legacy thinking from an AM strategy, and future materials that meet application requirements and provide for new opportunities. The Additive Snack Podcast is brought to you by EOS. Key Takeaways: [1:43] A general overview of polymer materials suited for 3D printing and why nylons are ideal. [6:21] Consider the minimum requirements when choosing a new material and be open to change to leverage AM. [8:52] Cary describes the base polymers, fillers, and new materials being used in AM. [14:23] An example of how Cary’s team designs and develops new materials to meet a client’s performance requirements. [20:55] Engineering variables to consider to control consistency and reproducibility of an AM process and output. [27:27] New applications and new frontiers being pushed by additive manufacturing solutions. [33:27] How and why to separate legacy thinking from a polymer AM strategy. Shareables: “The most effective way to target new applications in laser sintering is by having an openness and an understanding that your specification might have to change to accommodate a new material.” — Dr. Cary Baur, Sr. Manager, Polymer Technology, EOS on The Additive Snack Podcast ”Many customers enter additive manufacturing by actually converting existing parts first with the roadmap later of designing specifically for the process.— Dr. Cary Baur, Sr. Manager, Polymer Technology, EOS on The Additive Snack Podcast “We are more and more being tasked with understanding the variables that we can control understand the variables that could we can monitor and understanding what we cannot control .”— Dr. Cary Baur, Sr. Manager, Polymer Technology, EOS on The Additive Snack Podcast
33 minutes | Aug 26, 2021
Additive Manufacturing (AM): New Materials Influence the Future
We are entering a golden era for 3D printable metal materials. This means manufacturers in many industries will be able to create things they never have before. Host Fabian Alefeld speaks with Dr. Ankit Saharan, Senior Manager of Metals Technology at EOS. Today’s discussion focuses on the past, the present, and the future of metal additive manufacturing (AM) materials. The future takes center stage because a new class of 3D printable superalloys, Metal Matrix Composites (MMC), high entropy alloy, and pure metals will enable incredible new applications for the space industry, semiconductor industry, electronics industry, and many other verticals. Ankit explains what MMCs or high entropy alloys are and what they mean in terms of exciting new applications. The Additive Snack Podcast is brought to you by EOS. Key Takeaways: [1:27] Ankit shares the history of additive manufacturing using metals and how it unlocked future potential. [6:42] How AM evolved from a centering process into a serial production technology. [9:31] When developing custom projects with new materials initial resistance will be a challenge. [15:56] Metal Matrix Composite and High-entropy alloys: What they are, the benefits, and what they mean for the future of additive manufacturing. [22:28] Choosing one material or a process over another comes down to performance over substitution. [26:01] Artificial intelligence and new materials escalate the future of AM. Shareables: “Materials and processes go hand-in-hand. No matter how much you try to separate them, they always go hand in hand.”— Ankit Saharan, Senior Manager of Metal Technology, EOS, on The Additive Snack Podcast “We've got much better tools at our disposal like machine learning, artificial intelligence that we've never had before. It enables us to not only iterate faster in terms of material composition but also be able to predict what they are going to give us before we even make these materials physically.”— Ankit Saharan, Senior Manager of Metal Technology, EOS, on the Additive Snack Podcast “We are reaching a tipping point in additive manufacturing. AM can not be removed out of the supply chain anymore because it produces components that can not be produced with any conventional manufacturing technology anymore.” —Fabian Alefeld, EOS and Host of the Additive Snack Podcast
32 minutes | Jul 28, 2021
Additive Manufacturing (AM) Culture and Building a Successful AM Business
Host Fabian Alefeld speaks with Markus Seibold, Vice President of Additive Manufacturing at Siemens Energy and Material Solutions, two of the most advanced users of Additive Manufacturing (AM) consumer production. Markus and Fabian discuss why a working culture focused on growth and a shared sense of purpose is far more effective than a culture focused strictly on performance, best practices for creating and nurturing a growth mindset for teams, the bold moves Siemens Energy has made to successfully enable innovation through Additive Manufacturing, and why AM engineers and designers don't get enough credit. The Additive Snack Podcast is brought to you by EOS. Key Takeaways: [1:32] Markus has two diverse roles — driving AM into Siemens Energy’s core product base and expanding the Material Solutions business. [4:09] Siemens energy's approach to creating and nurturing a 'bigger than business' culture within a team of engineers. [10:28] A growth mindset pushes the limits of Additive Manufacturing through technological and adoption barriers. [16:05] Markus requested a budget and resources be moved into AM technical design teams. [24:30] Siemens Energy is pushing the limits of pure additive-only designs for higher efficiency and lower emissions. Books Mentioned: ● Tribal Leadership: Leveraging Natural Groups to Build a Thriving Organization by Dave Logan, John King, and Halee Fischer-Wright● Mindset: The New Psychology of Success by Carol Dweck Shareables: “I fundamentally believe in the mid-to-long run, a growth culture totally outperforms a performance culture.” — Markus Seibold, VP of AM, Siemens Energy & Material Solutions on The Additive Snack Podcast “If we really want to accelerate the additive application development, we said, we need to, on purpose, put budget and headcount against additive applications. So, we created 30 new headcount requisitions.” — Markus Seibold, VP of AM, Siemens Energy & Material Solutions on The Additive Snack Podcast “I can truthfully now claim that we [Siemens Energy] are the tipping point where additive is not only a technology push from a few but where it is getting toward a technology pull from many.” — Markus Seibold, VP of AM, Siemens Energy & Material Solutions on The Additive Snack Podcast
37 minutes | Jul 15, 2021
Additive Manufacturing Standards: Influence the Future of Industry with Mohsen Seifi
ASTM is an international standards organization that develops and publishes the standards that influence every step of the Additive Manufacturing process chain. These standards are not created in a silo. They are based on consensus and input from end-users, OEMs, government agencies, trade associations, and more. Therefore, individuals can play an active role in shaping standards and influence the future of Additive Manufacturing systems. Host Fabian Alefeld speaks with Mohsen Seifi, the Global Director of AM Programs at ASTM International about how standards are created, which standards are important to the AM journey, and how you can and should get involved. Key Takeaways: [1:38] Mohsen describes ATSM’s involvement in the AM process and current efforts of the organization. [6:22] How standards help the AM industry to accelerate and why it’s important for individual contributors to get involved. [10:54] Key standards in the AM process chain. [22:07] Mohsen shares an example of how a standard has impacted the core of the AM process. [28:58] Best practices and tips and tricks for an AM Qualifications/Quality Engineer. [31:18] Mohsen shares his background in material science and engineering and his journey to his current position as a Director of Global AM Programs. Shareables: “Due to the nature of the standard development processes which are consensus-based and voluntary, the pace of a standardization is not rapid.” — Mohsen Seifi, Director Global AM programs, ASTM on The Additive Snack Podcast “The success of any high impact technology requires consistency, quality, repeatability, and ultimately scalability.” — Mohsen Seifi, Director Global AM programs, ASTM on The Additive Snack Podcast “In the AM process, you have two main choices: you can either sit back and wait for the standards to be developed and to become available, or you can roll up your sleeves and contribute to the development and influence the direction.” — Mohsen Seifi, Director Global AM programs, ASTM on The Additive Snack PodcastThe Additive Snack Podcast is brought to you by EOS.
53 minutes | Jun 25, 2021
Additive Manufacturing Strategies: A Chat with a Panel of Industry Experts
Additive Manufacturing (AM) of parts can take many shapes, from steel parts on trains to coat hangers, from rugged tools on tactical vehicles to components on electric supercars. That's a wide variety of applications but no matter the industry and no matter the use case, there are consistent best practices to help you identify your first AM part. You also need to consider how to select the best AM technology for your needs, how to choose the materials you want to use, and how to scale up your AM production. Host Fabian Alefeld welcomes an all-star guest panel to share their expertise on the past, present, and future of AM. Stefanie Brickwede, Head of AM at Deutsche Bahn, John Wilczynski, Executive Director of America Makes, and Florian Lassan, Senior Business Development Manager of 3YOURMIND offer insights for the next generation of AM parts and applications. Key Takeaways: [1:53] Stefanie describes her roles and how MGA works to lower the hurdles of AM. [3:23] John describes the goal of America Makes and his role in the organization. [5:20] Florian describes the 3YOURMIND business model. [6:55] How John discovered his first AM parts and how he calculated the total ownership costs. [11:34] Convincing colleagues to adopt 3D printed parts was one of Stefanie’s first challenges at Deutsche Bahn. [15:37] Florian’s group was tasked to design a control part for an electric supercar. [18:40] Strategies for success in finding AM parts should mirror the overarching corporate strategies of an organization. [24:45] Advice about how to implement AM into a supply and value chain. [31:40] Stefanie details the process Deutsche Bahn created to accelerate the printing of parts to 25,000. [34:25] The importance of specifications and standards when scaling from conventional to additive manufacturing. [42:11] Advice from Florian and Stefanie about integrating AM strategies into an existing organization and convincing nonbelievers to use the technology. Shareables: “How do we get more people to understand where it fits, how it fits, where to use it, when not to use it? We do it primarily through the three main pillars of our organization. Those are the development of technology, development of the educational or kind of workforce community, and development of the ecosystem meaning it’s the community that's ultimately going to take the technology and do something with it.” — John Wilczynski, Executive Director, America Makes on The Additive Snack Podcast “The next parts we printed were metal and this is really crucial because we really had problems to convince our colleagues in the maintenance sides that 3D printing is a technology you can rely on and as much as something to print the Star Wars figurines.” — Stefanie Brickwede, Head of AM, Deutsche Bahn on The Additive Snack Podcast “Manufacturing a tool for injection molding for such a low number of parts does not make sense. It was a good use case for additive manufacturing to manufacture that component. So, we optimized the design to cool this electric component and we used the freedom of design with additive to put some lightweight design for the part.” — Florian Lassan, Sr. Business Development Manager, 3YOURMIND on The Additive Snack Podcast The Additive Snack Podcast is brought to you by EOS.
23 minutes | Jun 8, 2021
Mastering Post Processing for Polymer Additive Manufacturing
Post-processing is more than just the final finishing of a part. It needs to be integrated into the design phase of a project. In this episode, we dive into post-processing and finishing systems. It's a step that can add incredible value to your 3D printed product if done correctly. Many companies consider post-processing to be an afterthought, or they ignore it until it's too late and it is a big mistake because post-processing is such a vital part of any successful additive manufacturing initiative. CEO and Co-founder of DyeMansion, Felix Ewald and host Fabian Alefeld discuss why post-processing is a big value driver for 3D printed products, the dreaded triangle of complexity, the post-processing options you should consider on your additive manufacturing journey, and how to develop application-specific post-processing workflows to exactly match the requirements in different industries and applications. [1:37] DyeMansion’s first endeavor was a disappointment that ultimately led the organization to where it is today. [4:40] Post-processing changes the game when it comes to 3D printed eyewear frames. [6:37] The triangle of complexity is design, print and material, and finish. [7:52] Felix takes a deep dive into post-processing technologies. [15:13] The three ways to get color for consumer applications. [17:44] How developers can ensure high-quality, reproducible results. The Additive Snack Podcast is brought to you by EOS.
42 minutes | May 18, 2021
Reinventing Kids’ Eyewear with Additive Manufacturing…and a Touch of Disney Magic
This episode is an example of how organizations can use additive manufacturing to its fullest benefit, such as customized parts, complex structures, and small batch sizes. We discuss the opportunity of understanding the limits of current manufacturing methods to create a high-performing product, offers a better user experience, is swiftly created, and is potentially more affordable than existing products. Chief Product Officer, Katie Brandeau describes how Fitz Frames has revolutionized the eyewear market using AM. Fitz created a face-scanning app that automatically creates the perfect fit for their 3D-printed glasses. It is a unique approach to product design that combines full customization with style in very little time.[1:49] Katie describes her journey from R&D at Disney to Chief Product Officer of Fitz Frames. [4:26] Fitz Founder, Heidi Hertel recognized a need in the children’s eye care market and created a solution that included additive manufacturing. [11:13] Guidance for engineers who want to know if an additive manufacturing solution is right for their application. [17:28] Disassembling the historical product design process was the key to reinventing the design process and integrating additive manufacturing. [21:29] Katie describes an example where Fitz integrates the scan to print features to create truly customizable products in very little time. [27:58] Creating a non-breakable hinge for kid’s glasses is an ingenious way Fitz Frames is disrupting the market and revolutionizing the eyewear industry. [31:32] Considerations and mistakes companies make when incorporating additive manufacturing into the design process and product creation. The Additive Snack Podcast is brought to you by EOS.
27 minutes | Mar 16, 2021
Digitalization and Additive Manufacturing with Shane Fox
Digital Transformation and Industry 4.0 are phrases that have dominated every industry on the planet for the past few years. But what exactly do they mean and how do they apply to real-world manufacturing? In this episode, we take a deep dive into the state of the art capabilities of today's additive manufacturing, the smart way to begin your digital transformation journey, and how to see through the buzzwords and focus on the practical benefits. Co-founder and CEO of Link3D, Shane Fox helps us demystify the entire concept of digital transformation. Link3D works on the frontlines of the digital transformation journey. They partner with organizations to help them optimize their additive manufacturing workflows. [2:14] Link3D will focus on client solutions that allow them to move into a predictive state of manufacturing. [5:48] Creating a digital transformation strategy for additive manufacturing. [12:53] Build a team that shares the same long-term vision for a digitized production environment. [14:59] The importance of looking beyond the machines to shifting infrastructure from on-premise to cloud computing. [22:36] Link3D considers the full value stream of the production environment. The Additive Snack Podcast is brought to you by EOS.
23 minutes | Feb 16, 2021
From Prototyping to Successful Business Models with Additive Manufacturing - Güngör Kara
Additive Manufacturing has been predominantly closed away in Research and Development departments for some time. But, as timely, justified additive manufacturing solutions emerge it is time for many companies to move from prototype to production. The chain of processes leaders implement now will affect the future use of industrial 3D printing within an organization. In this episode, Chief Digital Officer of the medical and mobility powerhouse, Ottobock, Güngör Kara shares key insights about team building, implementing additive manufacturing, how organizations can create radical innovations, and the greatest challenges leaders face when moving additive manufacturing from prototype to production phase. Key Takeaways: [1:05] Three key learnings of additive manufacturing implementation. [4:02] Creating an additive manufacturing team must also include the problem and solution teams. [6:58] The initial rapid prototyping phase requires C-level attention and support. [9:13] The greatest challenges of moving additive manufacturing out of prototyping and into production. [12:37] Leaders must push the limits of their team to create radical innovation. [18:05] The two dimensions of scaling from one product to multiple products. The Additive Snack Podcast is brought to you by EOS.
36 minutes | Jan 15, 2021
Unlocking Higher Performance 3D Printing Applications with Brad Rothenberg
Additive Manufacturing has re-written many rules of product and part design. It has helped to improve part performance, cost of parts, and sustainability, all via design innovation. Engineers have the ability to creatively re-invent manufacturing from the ground up. Given this new freedom in the design process, what is the best way for an organization to capitalize and exploit the possibilities? In this episode, Founder and CEO of the engineering software company, nTopology, Brad Rothenberg, shares the key elements to unlock the full potential of 3D printing. He discusses the ability of software to re-shape the future of product design, the innovative tools that allow designers to replace grunt work with creativity, and what not to do when designing products for additive manufacturing. The Additive Snack Podcast is brought to you by EOS. Key Takeaways: [1:01] How nTopology’s engineering software fills the void in additive manufacturing design tools left by traditional manufacturing systems. [5:58] The creative role of the human engineer in the design process of additive manufacturing. [11:24] What not to do when creating products using additive manufacturing. [20:03] Brad Rothenberg shares a fascinating example of how new design tools and human creativity developed an application for the airforce that would not have been possible in the past. [24:23] Tips for engineers to accelerate design and engineering efforts. [27:22] Software allows engineers to build a re-usable knowledge base of design capabilities. [29:43] Brad shares his thoughts on where additive manufacturing will be in 5 years and how engineers can leverage their expertise. Bradley Rothenberg is the founder and CEO of nTopology, an advanced software company based in New York City that focuses on enabling engineers to design, manufacture and ship high-performance products in the least amount of time. nTopology’s breakthrough computational-modeling technology unifies geometry and simulation results into finely tuned manufacturing models, supporting engineers as they collaborate to develop lightweight, optimized parts with functional requirements built right in. Bradley studied architecture at Pratt Institute in Brooklyn, New York, and has been developing computational design tools for advanced manufacturing for the last 10-plus years.
24 minutes | Dec 15, 2020
How to Start Your Additive Manufacturing Journey with Wilderich Heising
The factory of the future will be a blend of traditional manufacturing and additive manufacturing. In fact, additive manufacturing is on track to take one percentage point of the $250-350 billion dollar manufacturing market by complementing existing technologies with additional capabilities. In this podcast, we examine the big picture of additive manufacturing, the value it can bring to your organization, the best ways to start your additive manufacturing journey, and how additive manufacturing can improve your competitive advantage. This conversation is a ‘state of the union’ for additive manufacturing. We examine where the industry is right now, how additive manufacturing can immediately meet industry needs, and the future integration of additive manufacturing into the traditional manufacturing market. The Additive Snack Podcast is brought to you by EOS.Wilderich Heising is a core member of Boston Consulting Group's Operations Center and a leader of BCG's manufacturing and supply chain work. Wilderich has worked with clients on manufacturing and supply chain strategy and network optimization, as well as advanced manufacturing topics such as additive manufacturing/3D printing, digitization of operations and Industry 4.0.
2 minutes | Nov 30, 2020
Introducing: Additive Snack
Brought to you by global additive manufacturing leader EOS, Additive Snack delivers the expert insights, interviews, and real-world stories that help you and your business achieve growth as well as success through additive manufacturing. I’m Fabian Alefeld, the host of Additive Snack and I lead the Additive Minds consulting team for EOS in North America. For years, we’ve helped businesses of all sizes explore the possibilities of AM and achieve success. Now we want to help you. Additive Snack is a forum for expert insights, best practices, and common mistakes to avoid on your AM journey. It’s no marketing B.S. and no product pitches. Just the education, inspiration, and information you and your organization needs to drive business growth – one step at a time. We know AM can be confusing. We know the path forward can be complex. Additive Snack is here to bring clarity to the chaos. Get ready to feed your AM knowledge and find your path to success.
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