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Additive Snack

EOS's podcast on additive manufacturing and industrial 3D printing, with interviews and real-world stories from engineers, specialists and users of the technology.

108 episodes · 80 hours · since 2020

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Additive Snack is filed under manufacturing, design and interviews. Its most recent episode published on , so it is still actively publishing. Listeners have left 13 ratings on Apple Podcasts, averaging 5 out of 5.

Latest episodes

The 10 newest episodes of Additive Snack, each with a summary and chapters.

  • · 1h 02m

    When Production Overtakes Prototyping: Materialise’s Next Phase of AM

    Bart van der Schuren, CTO of Materialise, explains how the company transitioned from a 1995 service bureau to a production powerhouse, recently surpassing prototyping with serial manufacturing. He details the three pillars of Materialise—manufacturing, software, and medical applications—and highlights rapid adoption in hearing aids, dental, and drones, contrasted with the slow, recertification-heavy aerospace sector. Van der Schuren argues that AI-driven automation and in-situ quality control are critical for reducing New Product Introduction (NPI) costs and scaling production in regulated industries.

    Scaling productionAI & machine learning
    10 chapters

  • · 1h 02m

    U.S. Navy's Captain Deichler on AM in the Submarine Industrial Base

    Captain Jason Deichler, Chief of Staff for Submarine Programs at the U.S. Navy, explains the Navy's strategy to achieve a 'one plus two' production goal (one Columbia-class and two Virginia-class submarines annually) by rebuilding a strained industrial base through additive manufacturing (AM). He details how AM addresses workforce shortages, supplier attrition, and lost casting/forging capabilities, moving from qualifying individual parts to establishing qualified material and process standards via Project Peculiar Documents (PPDs). The conversation covers the transition from skepticism to adoption, the scaling of qualified parts from 25 to 75, and the future vision of tens of thousands of additive parts integrated into submarine sustainment and new construction.

    Materials & manufacturing processesManufacturing partners & offshoring
    10 chapters

  • · 44m

    Building Drones at Scale: SLS Production from Low-Volume to High-Rate Manufacturing

    Nick Classen, General Manager of Northwest Rapid Manufacturing, explains how the company evolved from supporting Northwest UAV into a high-rate production provider for UAVs using EOS SLS technology. He details the shift from prototyping to end-use parts, highlighting specific applications like conformal fuel tanks, EMI-shielded housings, and structural brackets made from Nylon 12, Alumide, and glass-filled polymers. Classen discusses the operational challenges of scaling production, the critical role of post-processing, and the company's strategic expansion into metal AM (DMLS) to meet growing defense and aerospace demand.

    Scaling productionMaterials & manufacturing processes
    10 chapters

  • · 55m

    The AM Sasquatch: Challenging AM Qualification with Math, Physics, & AI

    Harshil Goel, founder and CEO of Dyndrite, explains how current additive manufacturing qualification practices lock down variables like software, machine, and layer height, stifling innovation. He details Dyndrite’s role in three America Makes programs: AI4AM, which uses statistical methods to reduce specimen counts for material allowables; DeltaQual 2.0, which enables 'bracketed qualification' allowing parameter changes within a defined window without requalification; and Gotham, which transfers qualified parameters across different machines and sizes. Goel introduces 'Sasquatch,' a physics-based framework using non-dimensional ratios (e.g., energy density) to bound process windows, aiming to accelerate industry adoption within a two-year timeline.

    Certification & complianceEmbedded firmware
    7 chapters

  • · 1h 08m

    AM as a Moat: How Annihilator Created a Competitive Advantage in Broadhead Manufacturing

    Brandon Brodie, co-founder and CEO of Annihilator Broadheads, explains how a failed elk hunt inspired the creation of a broadhead with a unique 'scoop' design that creates high-pressure and low-tension wound channels. After validating the concept through plastic prototypes and an improvised Instant Pot wind tunnel test, Brodie faced severe supply chain failures with investment casting and metal injection molding suppliers, leading to massive scrap rates and lost dealers. To save the company, he brought metal laser powder bed fusion in-house, learning to operate 5-axis CNC grinding and metal printing to achieve tight tolerances and enable complex geometries like the Katana broadhead. Brodie outlines how this additive manufacturing moat allows for rapid innovation, new product lines, and future contract manufacturing partnerships.

    Scaling productionManufacturing partners & offshoring
    7 chapters

  • · 49m

    AI Is Getting Hot: Can Additive Manufacturing Help Cool It Down?

    Professor PS Lee, founder of CoolestDC and head of Mechanical Engineering at the National University of Singapore (NUS), explains how additive manufacturing (AM) enables complex unibody cold plates that reduce junction temperatures by ~10°C and pumping power by 60–70% in AI data centers. He details the transition from single-phase to two-phase direct-to-chip liquid cooling and the deployment of AM cold plates at NUS’s Sustainable Tropical Data Center Testbed (STDC), which features 22 liquid-cooled racks and ~500 kW capacity. Lee discusses system-level challenges, including leakage risks, total cost of ownership (TCO) evaluations, and the potential for AM in space-based data centers and waste-heat reuse.

    Mechanical engineeringMaterials & manufacturing processes
    10 chapters

  • · 1h 00m

    Inside GM's Additive Industrialization Center with Ante Lausic

    Ante Lausic, Lead Process Engineer at General Motors' Additive Industrialization Center (AIC), explains that scaling additive manufacturing (AM) in automotive requires AM-native designs, automotive-grade materials, and cost-effective production rather than just faster machines. He details how GM uses the AIC to validate technologies and supports high-value, low-volume applications like the Cadillac Celestiq, which incorporates over 130 AM components including safety-critical parts. Lausic highlights significant growth in tooling and end-of-arm tooling, while noting that scaling to high-volume vehicles like the Corvette remains challenging due to material limitations and qualification hurdles like PPAP.

    Scaling productionMaterials & manufacturing processes
    14 chapters

  • · 1h 14m

    Why AM and Orthotics & Prosthetics are the Perfect Fit

    Brent Wright, VP at EastPoint Prosthetics and co-founder of Life Enabled, explains how additive manufacturing is transforming orthotics and prosthetics (O&P) by replacing hazardous, non-digital traditional workflows with scalable, data-driven digital processes. He details the shift from plaster casting and carbon fiber layups to pressure casting, 3D scanning, and SLS printing with materials like PK5000 to create flexible sockets that heal wounds and improve comfort. Wright discusses the challenges of scaling care in developing regions like Guatemala through local manufacturing and modular kits, while noting that reimbursement barriers in the US limit the adoption of advanced sensors and actuators.

    Materials & manufacturing processesScaling production
    10 chapters

  • · 41m

    AM at a Crossroads: Incodema3D Proves What's Possible at Scale

    Sean Whittaker, founder and CEO of Incodema3D, explains how the company evolved from a sheet metal prototyping shop into one of North America's largest metal additive manufacturing operations, now scaling to over 50 Laser Powder Bed Fusion (LPBF) systems. He details the strategic shift from prototypes to high-volume production, emphasizing vertical integration, the maturity of Design for Additive Manufacturing (DfAM), and the critical role of AFM Capital's investment in accelerating expansion. Whittaker highlights specific applications in thermal management, defense, and energy, noting how reshoring and automation are driving the industry's transition into a scalable, capital-intensive manufacturing model.

    Scaling productionDesign for manufacturing & NPI
    10 chapters

  • · 1h 58m

    AM Rocket Engines and Space Nuclear Power with Omar Mireles

    Omar Mireles, Director of Manufacture and Materials at Space Nuclear Power Corporation (Space Nukes), discusses how additive manufacturing (AM) accelerates the development of space nuclear reactors and liquid rocket engines. He details his career at NASA, Oak Ridge, and Los Alamos, focusing on the challenges of printing refractory metals like niobium and tungsten, and explains Space Nukes' goal of delivering safe, affordable power anywhere in the solar system using a Krusty design heritage. Mireles outlines an aggressive ~2-year flight timeline, noting that heat rejection and regulatory barriers are the primary constraints, while AM enables part consolidation and weight reduction in complex geometries.

    Mechanical engineeringMaterials & manufacturing processes
    9 chapters

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