Being an Engineer · 24 Oct 2025 · 56m · Episode 43
Greg Mark, founder of Markforged and Backflip.ai, discusses the mechanical robustness of Markforged 3D printers, including kinematic couplings and rail alignment, and their adoption by the US Marines and NASA. He details the origin of Backflip, an AI tool that converts 3D scans and STL files into parametric CAD models for SolidWorks and other platforms, aiming to democratize design for technicians. Mark also shares entrepreneurial lessons on product focus, citing the development of Onyx material and the importance of reliability over speed in early Markforged iterations.
Where this conversation describes AI being used to build or deliver a product. Part of the AI in practice tracker.
DesignBackflip.ai
A SolidWorks plugin uses AI to analyze an imported mesh and drive the CAD software to build the part, providing four options for the user to select and allowing them to watch the AI construct the feature tree for educational purposes.
“we'll give you four options. … it senses all it works. And then literally drive SolidWorkss. And like rotation and like builds you your part.”
Greg Mark · Hear it at 28:14
companies scaling up and early-stage companies
Other shows on the same ground, closest first.
Greg Paulsen, Director of Applications, Engineering and Marketing at Xometry, discusses the complexities of rapid prototyping and the transition to mass production. He details the pros and cons of various 3D printing technologies, including filament-based FDM, powder bed fusion (SLS, MJF), and resin-based methods (SLA, DLS), explaining how each affects design constraints and scalability. Paulsen highlights common hardware horror stories, such as designing for 3D printing without considering injection molding requirements, leading to prohibitive costs and tooling issues. He emphasizes the importance of clear communication with manufacturers and using AI-driven tools to optimize designs for manufacturability early in the process.
Michael Yim and Jonathan Tai, co-founders of Hatch Duo, an AI-enhanced industrial design and engineering studio, discuss their journey from bootstrapping to serving early-stage hardware startups. They detail their 'design capital' model, where they invest in-kind to help pre-seed companies build prototypes to secure funding, and explain how they blend human creativity with AI tools like FLO.ai to enhance efficiency. The conversation covers the importance of brand identity, the challenges of working with first-time founders, and their strategic use of social media for client acquisition.
Bar Smith, founder of Maslow CNC, explains the evolution of the Maslow 4.1 large-format CNC router, detailing the transition from a scrappy, open-source garage project to a polished product via a successful Kickstarter. He discusses key engineering decisions, such as switching from stepper to servo motors and using a ring-based linkage system to solve complex kinematic math, while highlighting the importance of community feedback and transparent communication in iterative hardware development. Smith also reflects on his decision to step away from the project, work in the industry, and return to shepherd the product, aiming to commoditize large-format CNC technology to the accessibility of a standard chop saw.
Ryan Zellers, founder of V1 Engineering, explains how his passion for making things led to the creation of the Mostly Printed CNC (MPCNC) and the growth of his company. He details his journey from working at Robo 3D and a medical device firm to bootstrapping V1 Engineering from a garage, leveraging the Thingiverse community for design feedback and sales. Zellers discusses his deliberate choice to remain a solo operator, using automation and contractors to handle logistics while he focuses on product design and community engagement.
Joe Hebenstreit, CEO of Shaper, and Adi Rao, Product Lead at Shaper, discuss the evolution of Shaper Origin from its early prototyping days to its current ecosystem of hardware and software. They detail the development of Shaper Studio, a simplified digital design tool for craftspeople, and Plate, a precision jig that blends analog woodworking techniques with digital tracking. The conversation highlights Shaper's philosophy of augmenting human skill rather than replacing it, targeting both experienced woodworkers and digital natives.
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