Additive Snack

Host Fabian Alefeld interviews Erin Mastroni, President and founder of I3D Manufacturing (founded 2013), about building one of the largest additive-focused contract manufacturers and the industry’s shift from prototyping to production. Mastroni describes moving from fashion retail and trend forecasting to an MBA in sustainable business, spotting production AM as a key trend, and launching a metal powder bed fusion business in Oregon with limited traditional manufacturing experience. She recounts early funding challenges, using SBA/New Market Tax Credits, and landing Blue Origin as an early customer, which helped establish I3D as a fast-moving development partner known for tackling difficult materials like titanium and new nickel alloys with EOS. I3D grew from 5 people and two machines to two campuses, ~30 machines, and 54 employees, is launching an internal “I3D Academy,” navigated a severe COVID revenue drop without layoffs, and was acquired in 2023 by BTX Precision (L Squared Partners), expanding into turnkey CNC and broader capabilities while discussing PE’s role, production scalability, and emerging AI opportunities.

00:00 Podcast welcome
01:47 Fashion to additive
04:27 Funding and mission
06:52 Blue Origin breakthrough
08:27 Becoming a dev partner
12:19 I3D today scale
15:29 Growing talent academy
17:05 Growth phases and pandemic
20:22 Acquisition and turnkey expansion
22:06 Private equity tipping point
27:43 Private Equity Momentum
28:41 Flow Driven Applications
32:54 Supply Chain Use Cases
35:12 Scaling Production Know How
40:21 One Stop Shop Strategy
43:14 Customers Get Smarter
47:31 Next Wave Breakthroughs
53:03 AI In Additive Manufacturing
57:25 Closing Thanks

Fabian Alefeld hosts Duann Scott on the Editor Snack podcast to discuss how AI is evolving in additive manufacturing, moving from “AI-washing” and impractical text-to-mesh hype toward more capable tools using language models, visual language models, surrogate models, and emerging foundational models. Scott describes testing tools by trying to make them fail and highlights a recent success with the Raven plugin for Rhino/Grasshopper, which generated a parametric VESA mount and tripod adapter from minimal prompts, then iteratively added fillets and an isogrid structure and produced a printable part within hours. They discuss constraints like missing engineering training data and design intent, the promise of AI for toolpath and process optimization (including transfer of parameter knowledge across materials), and the role of the 3MF format in capturing toolpath and metadata to enable richer, searchable datasets. Scott previews CDFAM events in Barcelona, DC, and Tokyo and emphasizes that progress requires significant data work and investment.
 
 
00:00 Welcome and Guest Intro
 
02:18 AI Hype to Real Progress
 
04:13 Testing AI Design Tools
 
04:46 Data Gaps and Design Intent
 
07:15 Two Paths for AI Design
 
10:15 Raven Grasshopper Breakthrough
 
13:17 Pushing Parametric Complexity
 
20:28 Limits of Black Box Optimization
 
22:40 Toolpath and Material Transfer
 
26:18 Alloy Discovery and Qualification
 
28:05 3MF Role Teaser
 
28:18 3MF Format Overview
 
29:17 Smarter Toolpath Extensions
 
32:31 Metadata for AI Training
 
35:43 Data Ownership and Synthetic Data
 
39:59 AI Impact on Additive
 
44:10 Workforce and Reshoring
 
47:22 What Is CDFAM
 
49:49 CDFAM Audience and Format
 
51:43 DC Event and Government
 
54:05 Wrap Up and Thanks

In this episode of the Additive Snack Podcast, host Fabian Alefeld is joined by Oliver Elbert, Head of Additive Manufacturing at Grenzebach, to discuss the pivotal role of automation in scaling additive manufacturing. They delve into Grenzebach’s extensive expertise in industrial automation and its recent ventures into additive manufacturing. The conversation covers the challenges and benefits of automating post-processing tasks, increasing equipment efficiency, and optimizing labor dynamics. They also explore notable projects like the Next Gen AM and the Polyline project, highlighting how automation can significantly enhance production availability and reduce manual intervention. Oliver provides insights into the integration of automated guided vehicles (AGVs), robots, and job exchangers in additive manufacturing, and discusses the future potential of fully automated production environments.
 
00:00 Introduction to Additive Snack Podcast
 
00:18 The Challenge of Automating Additive Manufacturing
 
01:07 Introducing Grenzebach and Oliver Elbert
 
02:22 History and Evolution of Grenzebach
 
06:33 Grenzebach’s Entry into Additive Manufacturing
 
08:31 The Slow Adoption of Automation in Additive Manufacturing
 
14:34 The Dual Setup Station and Its Impact
 
19:25 Automation Solutions for Various Industries
 
23:52 The Future of Automation in Additive Manufacturing
 
24:48 Challenges and Opportunities in Automation
 
34:13 The Role of Humanoids in Industrial AM
 
36:20 Conclusion and Future Outlook

In this episode of the Additive Snack Podcast, host Fabian Alefeld welcomes Kristin Mulherin, the Director of Additive Manufacturing Technology at Hubbell Inc., to discuss the creation and development of an additive manufacturing center of excellence within a 150-year-old corporation. Kristin shares her extensive journey through various roles in the additive industry, from Northrop Grumman to HP, and her significant input in initiatives like Women in 3D Printing. She discusses Hubbell's historical background and the strategic decisions behind establishing the AM center, including technology choices, cost management, and internal education to drive innovation. 
 
 The episode covers specific applications, the challenges of shifting from prototyping to production, and the importance of cross-departmental education within the company to leverage the full potential of additive manufacturing. 
 
00:00 Introduction to the Additive Snack Podcast 
 
01:40 Meet Kristen Mulherin: A Journey in Additive Manufacturing 
 
05:07 Kristen's Role at Hubbell Inc. and Industry Insights 
 
06:11 Women in 3D Printing and Leadership 
 
07:46 Building Hubbell Inc.’s Additive Manufacturing Center of Excellence 
 
15:25 Technology Stack and Future Plans at Hubbell 
 
19:30 Exploring New Opportunities in Additive Manufacturing 
 
21:38 Balancing Cost and Lead Time in Additive Manufacturing 
 
22:08 Value Drivers in Additive Manufacturing

In the second part of this two-part episode series of the Additive Snack Podcast, host Fabian welcomes Dr. Edward Herderick, Director of Education and Workforce Development at America Makes, to discuss the maturation of additive manufacturing. They delve into the evolution of the technology, its impact on the industry, and the importance of specialized education to foster a capable workforce. 
Dr. Herderick shares insights on the integration of creative and engineering disciplines, the need for hands-on experience, and the role of the investment community in driving the industry's growth. The conversation also touches on the significance of industry partnerships in reshaping education, making additive manufacturing more accessible, and preparing the next generation of skilled professionals.
01:33 The Evolution of Additive Manufacturing
02:12 Integration of Art and Engineering
05:00 Specialization in Additive Manufacturing
08:44 Industry Trends and Workforce Development
15:25 Additive Manufacturing in Education
39:50 Hands-On Experience and T-Shaped Expertise
50:55 Investment and Market Segmentation