Creating the Future of Energy with Dr. Alaa Elwany

The US has always been a hotbed of innovation. With the integration of additive manufacturing (AM), AI, and advancements in materials and manufacturing technologies, creating clean, abundant energy is within reach. This conversation highlights the role of AM in next-generation energy technology. 

Host Fabian Alefeld speaks with Dr. Alaa Elwany, science and technology policy fellow at the U.S. Department of Energy, Advanced Manufacturing Office. Alaa is a recognized expert in additive manufacturing and a key advisor in the realm of science and technology to the U.S. government. He is currently serving as a science and technology fellow at the US Department of Energy and as a professor at Texas A&M at the Department of Industrial and System Engineering. Fabian and Alaa talk about Alaa's experience within the DOE, the intersection of AM and energy, the future of smart manufacturing and digital manufacturing, and resources for business owners looking to expand their AM opportunities. 

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[1:24] Alaa explains his role within the DOE and how he and his team are shaping the future of energy. 

[3:36] Additive manufacturing is versatile and scalable enough to be used in major clean energy projects. 

[8:18] Materials that have a high relevance to energy applications. 

[11:38] Additive’s foundational role in increasing supply chain resilience.  

[16:48] Next-gen energy technology includes additive manufacturing. 

[20:48] The future of integrating smart manufacturing and AI into additive manufacturing.   

[30:33] The vital role of government investment, regulation, and support for the future of additive and smart manufacturing. 

The innovative and intricate world of Digital Foam is an evolution of polymer lattice structures. In the past, developing applications for polymer lattice structures, especially for performance applications, has been challenging. Challenges include aspects of design, printing, post-processing, and materials. All the value chain elements influence each other, adding more complexities. 

In this special episode, Host Fabian Alefeld speaks with four panelists from the Digital Foam Architects Network about the full process chain and the complexities and opportunities of Digital Foam. Joining the panel discussion are Pierre Gonnetan, business development manager at Arkema, Mike Schorr, general manager at DyeMansion, Nick Florek, CEO of General Lattice, and Dr. Dave Krzeminski, senior Additive Minds consultant at EOS. The goal of the Digital Foam Architects Network is to increase accessibility, scalability, and speed up development for performance-based lattice structures.  

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS. 

Key takeaways: 

[3:08] The history of polymer lattice structures and methodologies of production with Nick Florek 

[7:54] Dave Krzeminski on overcoming the challenges of an ever-changing technology 

[15:00] Objectives and initiatives of the Digital Foam Architects Network 

[19:41] Pierre Gonnetan on the material landscape and key drivers for digital foam applications 

[31:03] Mike Schorr on the importance of post-processing aspects of Digital Foam.  

[38:41] Mike Schorr explains the complex process of creating uniformity in powdering, coloring, and smoothing polymers.  

[48:48] Nick Florek unpacks the coordination and parameters of the digital design phase.  

[56:23] Additional industrial opportunities for Digital Foam applications.  

Resource Link:  

Arkema 

EOS 

DyeMansion 

General Lattice 

Consumer 3D printing and industrial additive manufacturing (AM) are more closely related than many in the industry realize. Supply chain considerations, material development, and the ever-growing need for a robust workforce are valid concerns for both movements. 

In this episode, Host Fabian Alefeld speaks with YouTube influencer and content creator Joel Telling, the 3D Printing Nerd. Together, they dive into the fascinating interface between consumer and industrial 3D printing. Joel transitioned from software development to becoming a leading voice in the 3D printing industry with more than 600k subscribers to his 3D Printing Nerd YouTube channel. Joel is a key voice in the industry, an additive expert himself, and a friendly face to EOS in the 3D printing industry.  

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS. 

Key takeaways: 

[1:56] The adoption of additive manufacturing in various industries has a lot to do with public perception.  

[8:55] Joel describes the challenge of integrating additive’s industrial applications with consumer products and applications.  

[17:15] How Joel transitioned from software engineer to the AM influencer, The 3D Printing Nerd. 

[21:23] How software engineering works within the additive manufacturing framework. 

[25:15] Why understanding the industrial and consumer side of AM is beneficial for the entire industry. 

[29:53] Joel’s recommendations for consumer machines and materials for newbies wanting to experiment with 3D printing projects. 

[40:16] Joel’s advice for those interested in 3D printing, find a community of like-minded people, and meet up. 

Picture a future where values and supply chains are robust and agile. The workforce is skilled in high-tech disciplines such as additive manufacturing (AM). And the manufacturing industry has taken back its important role, not only within the US but all around the world. This vision is currently being modeled in Vermont. 

Joining Host Fabian Alefeld is Barry Hulce, the Executive Director of Vermont’s Manufacturing Collaborative (VTMC). In this episode, Barry unpacks the complexities of modern manufacturing, dives into the challenges of workforce development, and reveals how his organization is constructing a robust manufacturing infrastructure that is set to accelerate the adoption of additive manufacturing. 

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[1:21] Industry agnostic, Barry enjoys working with systems that help people. 

[8:20] The purpose and intention of Vermont Manufacturing Collaborative. 

[12:09] How VTMC’s ecosystem will be duplicated and scaled for rural communities. 

[17:35] VTMC’s plan for increasing capacity and developing the future AM workforce. 

[23:31] How educating an AM workforce differs from conventional manufacturing technologies. 

[34:05] VTMC’s technological capabilities and the development stages of active products. 

Imagine printing a car part for the racing industry as your first additive manufacturing (AM) project, earning a process engineer position with Honda Aerospace, and following that up by becoming the AM technology leader at Ohio State University. This is the inspiring story of today’s guest. 

Joining host Fabian Alefeld is Ben DiMarco, AM Technology Leader and Principal Engineer at Ohio State University’s Center for Design and Manufacturing Excellence (CDME). In this conversation, they explore Ben’s contributions to lattice structures, process monitoring, and innovative technologies such as nLIGHT and cold metal fusion. They also touch on Ben’s role and passion for workforce development. 

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

[1:15] In 2009, Ben’s first printed AM part was a brake fluid reservoir used in the racing industry. 

[3:39] Ben describes the key characteristics of lattice structure and its impact on part performance. 

[8:18] For the past few years, Ben’s objective has been to create a semi-empirical model for lattice structures. 

[17:03] Ben’s vision for how his work will impact the AM industry. 

[22:03] An overview of nLIGHT technology and OSU’s beam shaping project. 

[32:14] Examples of current and future uses of artificial intelligence in additive manufacturing. 

[34:47] OSU’s forthcoming study includes the history and future of cold metal fusion. 

[39:21] Ben explains OSU’s CDME workforce development program. 

It is common to hear about productivity, materials, and laser power in additive manufacturing (AM). But stories are rarely heard about the lives being changed because of this technology. Innovation in AM is not just about technology. It is about transforming lives and creating a better future for people. 

Host Fabian Alefeld speaks with Princess Moshoana, a South African woman whose life was forever changed by a violent act and then restored through the marvels of AM and Dr. Gerrie Booysen, a leading figure in AM and Director of the Centre for Rapid Prototyping and Manufacturing at the Central University of Technology. Together, they share a journey of recovery and groundbreaking advancements in medical industrial 3D printing. 

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS. 

Key Takeaways: 

 
[1:31] Princess recounts the violent crime that left her physically and emotionally unable to smile. 

[7:11] Dr. Gerrie Booysen explains the history of the Centre for Rapid Prototyping and how they began 3D-printed patient-specific implants. 

[11:06] The arduous process chain of creating, implanting, and reconstructing Princess’ jaw with an AM printed part. 

[13:37] How additive manufacturing helped Princess regain her hopes and dreams. 

[15:14] The many ways AM devices and reconstructive surgery can meet the tremendous needs of South Africans. 

Resource Link:  Centre for Rapid Prototyping and Manufacturing 

The world of additive manufacturing (AM) is ever-evolving. While additive technology is a proven game changer, gaining a client's trust requires speed, agility, and simplicity, particularly in production and supply chain processes.

Joining Host Fabian Alefeld is Derek VanDenDriessche, Vice President of Sales and Business Development at Precision ADM. Precision ADM is a contract manufacturer specializing in AM. Derek has extensive experience in building successful AM production chains. He explains Precision’s three-step process from prototype to production, the value of partnering with a contract manufacturer, and the challenges of producing parts for the medical and aerospace industries.

All opinions expressed by podcast participant(s) are so current opinions and do not reflect the opinions of EOS GmbH or the podcast participant(s) respective companies and/or affiliates. 

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[3:31] Who is Precision ADM and how do they maintain supply chain agility? 

[8:36] Derek details Precision ADM’s 3-step process from prototyping to production.

[11:29] Derek explains the similarities and challenges of handling additive production for the aerospace and medical industries.

[13:31] What criteria demonstrate the value of partnering with a contract manufacturer versus vertically integrating additive production?

[18:26] How is Precision ADM pushing the additive manufacturing industry forward?

As additive manufacturing (AM) practices and processes mature, we are reminded daily of the boundless potential and transformative power of technology, especially in the healthcare industry. However, additive manufacturing can be a confusing arena for traditional medical manufacturers to step into. Large organizations that successfully integrate additive are essential components of the technology’s wider adoption.

Joining Host Fabian Alefeld is Mark Morrison, Senior Research Manager at Smith & Nephew. Mark has decades of experience in both additive manufacturing and material science. Their conversation explores the significance of material science in AM, Mark’s unique journey, and sheds light on Smith & Nephew’s achievements including producing hundreds of thousands of patient-specific applications. Mark highlights key applications driving AM adoption and the importance of porous structures in the medical space. They also address the patient-specific perspective, the challenges of integrating AM into big business, and how the industry is navigating the experience gap between traditional methods and modern industrial 3D printing.

All opinions expressed by podcast participant(s) are so current opinions and do not reflect the opinions of EOS GmbH or the podcast participant(s) respective companies and/or affiliates. 

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:55] Mark’s appreciation for understanding why things behave the way they do triggered his journey into material science and additive manufacturing.

[5:03] In the medical industry, what current applications can be enhanced by additive manufacturing, and what are the patient benefits?

[10:33] What challenges or limitations does Mark foresee for integrating additive manufacturing more broadly in the medical space?

[15:46] What role does the FDA play in assisting organizations to qualify additively manufactured implants to make them market-ready? 

[19:31] What excites Mark when he thinks about current and future additive applications?

With the top five orthopedic organizations using metal and polymer additive manufacturing for production parts, the space industry using it daily for critical applications, and the automotive industry ramping up, it means this is just the beginning of a very exciting additive manufacturing (AM) journey.

Joining Host Fabian Alefeld is Chuck Hansford, Director of Advanced Development at Tecomet. In the US, Chuck is widely known to be one of the most experienced metal additive manufacturing experts in the medical industry. He provides profound insights on where AM is currently as a technology and where it will be in the future, what makes clients adopt AM, and guidance for the next generation of AM innovators.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[:45] Chuck describes his early days of testing the boundaries of additive manufacturing in plastics, then metals.

[5:37] Chuck explains where the medical industry stands when it comes to adopting additive manufacturing.

[9:41] Chuck gets technical about the product development lifecycle, adoption of AM in the medical industry, and resolving trapped powder particles.

[23:00] What are AM adoption rates and trends in the medical space?

[28:27] Chuck’s key guidance for engineers, C-levels, and operators who may be skeptical about adopting additive manufacturing.

The impact of additive manufacturing (AM) is expanding within the medical industry. With customization and quick turnaround times for products essential for exceptional patient care, the vertical integration of additive and traditional manufacturing is making this requirement a reality. This paradigm can function as a role model that can be applied to other technologies and industries, further solidifying the benefits of its adoption.

Joining Host Fabian Alefeld is restor3D's brilliant co-founder and CTO Cambre Kelly. Cambre is a key figure behind the company's impressive success and recently joined the Forbes 30 under 30 list in the manufacturing and industry sector. In addition to sharing restor3D’s unique and innovative business model, Cambre explains how restor3D views the intersection of additive manufacturing, personalized healthcare, and artificial intelligence.

Comments about the show or wish to share your AM journey? Contact us at additive.snack@eos-na.com. The Additive Snack Podcast is brought to you by EOS.

Key Takeaways:

[1:16] Cambre describes her education, research, and career journey that led to her specializing in 3D-printed porous structures in orthopedics.

[3:35] Cambre delved into unexplored territory researching optimized gyroid lattice structures for orthopedics.

[6:52] Founded in 2017, restor3D has been successful in the complex task of vertically integrating additive and traditional manufacturing without outsourcing.

[16:08] In an effort to bring more personalized solutions to the orthopedic market, restor3D recently acquired companies that will expand their reach.

[20:33] Restor3D endeavors to be technology agnostic and utilize AI tools for design efficiencies.