# S2 E5: Rapid Prototyping Deep Dive with Greg Paulsen

- Show: [The Builder Circle](https://hardwarepodcasts.com/podcast/the-builder-circle)
- Published: 2024-01-23
- Length: 1h 06m
- Page: https://hardwarepodcasts.com/podcast/the-builder-circle/2024-01-23-s2-e5-rapid-prototyping-deep-dive-with-greg-paulsen
- Listen: https://rss.com/podcasts/thebuildercircle/1312207

## Summary

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.

## Outline

1. Introduction: Greg Paulsen and Xometry's Role in Manufacturing
2. Manufacturing Bias: How Available Tools Constrain Design
3. Powder Bed Fusion: SLS and MJF Mechanics and Benefits
4. Resin-Based Printing: SLA, DLS, and PolyJet Trade-offs
5. Hardware Horror Stories: The Cost of Poor Transition Planning
6. Metal 3D Printing: DMLS, Binder Jetting, and Aerospace Applications
7. Design for Additive (DFA) Pitfalls and Material Selection
8. AI in Hardware: Instant Quoting and Prompt-Based Design

## Topics

- [Prototyping & iteration](https://hardwarepodcasts.com/topic/prototyping)
- [Materials & manufacturing processes](https://hardwarepodcasts.com/topic/materials-and-processes)
- [Design for manufacturing & NPI](https://hardwarepodcasts.com/topic/design-for-manufacturing)
- [Scaling production](https://hardwarepodcasts.com/topic/scaling-production)
- [AI & machine learning](https://hardwarepodcasts.com/topic/ai-and-machine-learning)

## Most relevant to

early-stage companies

## Mentioned

- Xometry (company)
- SLS (other)
- MJF (other)
- SLA (other)
- DLS (other)
- FDM (other)
- Carbon (company)
- Formlabs (company)
- Adidas (company)
- Onshape (other)
- Autodesk Fusion 360 (other)
- Tanso 3d (company)
- Catify AI (company)

## Related episodes from other shows

- [Following Your Passion in 3D Printing with Greg Paulsen](https://hardwarepodcasts.com/podcast/manufacturing-happy-hour/2021-01-26-following-your-passion-in-3d-printing-with-greg-paulsen) (Manufacturing Happy Hour)
- [3D Printing and Additive Manufacturing with Steve Szymeczek of Penumbra Engineering](https://hardwarepodcasts.com/podcast/predictable-designs-podcast/2020-04-02-3d-printing-and-additive-manufacturing-with-steve-szymeczek-of-penumbra-engineer) (Predictable Designs Podcast)
- [203: Design for Manufacturing for a New Invention Product](https://hardwarepodcasts.com/podcast/product-startup/2023-11-24-203-design-for-manufacturing-for-a-new-invention-product) (Product Startup)
- [How Protolabs turns CAD files into parts in under 24 hours](https://hardwarepodcasts.com/podcast/the-robot-report-podcast/2026-08-14-how-protolabs-turns-cad-files-into-parts-in-under-24-hours) (The Robot Report Podcast)
- [193: 3D Printing Overview for New Inventions](https://hardwarepodcasts.com/podcast/product-startup/2023-09-14-193-3d-printing-overview-for-new-inventions) (Product Startup)

## Citing this page

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