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This episode of AM Insider features a special discussion on the history and evolution of the additive manufacturing (AM) industry. Hosts Justin Hopkins and Dustin Kloempken welcome Kevin Mortzfield, an industry veteran who began his career in late 1994, to share his extensive experience.

Kevin Mortzfield's background includes working at 3D Systems as an associate applications engineer, where he started with stereolithography (SLA) on machines like the SLA 250. He then moved to Masco Corporation, running various 3D printing technologies (SLA, SLS, Objet) and managing their R&D facility as a shared service for business units like Delta Faucet and Liberty Hardware. Later, he transitioned to the software side, working for Live Software and currently serving as a solutions engineer at Autodesk, with a focus on Fusion Additive and NetFabb Additive products. This diverse experience allowed him to witness the industry's progression from sales to customer, and then to software development and education.

The discussion covers several key aspects of AM's journey:

• Terminology Evolution: Kevin notes that when he started, it was primarily called rapid prototyping, which was a broader term. The term 3D printing emerged about ten years later, emphasizing the layer-by-layer build process, followed by additive manufacturing, which now encompasses a wider range of applications, including end-use parts.
• Early Applications and Challenges: In the early days, AM was used for form-fit parts and visualization, such as an eight-cylinder engine block that helped identify an interference in a water jacket. Significant challenges included Unix-based software that required manual input and high-end Silicon Graphics workstations. CAD files were often problematic, with issues like bad formats, holes in models, and incorrect parameters leading to distorted shapes or excessively large files. Support removal was also difficult, as solid plastic supports could easily crack parts.
• Technological Breakthroughs: Kevin highlights metal additive manufacturing (direct metal 3D printing) as a major game-changer, allowing for the creation of metal components directly from a 3D printer. The entry of big-name companies like HP into the 3D printing space also brought significant public attention and legitimacy to the industry. The evolution of software from OEM-specific to independent solutions (like Materialise and NetFabb) and eventually integration into CAD packages (like Autodesk Fusion Additive) has greatly enhanced usability and efficiency.
• Successful "Boring" Applications: The episode touches on applications that, while not always glamorous, have proven highly successful and valuable. These include investment casting patterns for complex metal parts (like those used by SpaceX for rocket bodies) and injection molding with conformal cooling lines, which significantly improve manufacturing processes and reduce costs.
• Staying Current and Industry Impact: With the rapid proliferation of different 3D printers—from hobbyist machines to high-end production systems—Kevin emphasizes the importance of staying informed through newsletters (e.g., Additive Manufacturing Media, TCT Magazine, 3D Printing Industry) and attending trade shows like Rapid and AMUG. He stresses that AM has profoundly impacted various industries, including healthcare, manufacturing, and design, becoming an indispensable tool.
• Future Outlook: Looking ahead, Kevin predicts exciting developments in bioprinting (organs, skin) within 5-10 years, as well as large-scale 3D printing in construction for houses and bridges. The conversation also delves into the grow

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This episode of AM Insider, hosted by Justin Hopkins and Dustin Kloempken, dives deep into the cyclical nature of innovation and adoption within the additive manufacturing industry. The discussion explores the recurring challenges and breakthrough moments that have shaped its journey from the early days to the present.

I. Innovation Cycles in Additive Manufacturing (AM)
The AM industry evolves in waves, with renewed excitement and innovation every 7–10 years. Companies have shifted from a “build it and hope” mindset to a market-first approach, identifying customer needs before developing products. Early sales often involved overpromising, but today’s focus is on targeted, strategic product development.

II. The Power of Influencers and Advisors
Industry growth is driven not just by technology, but by trusted voices—visionaries and advisors who shape perception and build momentum. In the past, reliable information was scarce. Now, respected figures and platforms help validate and promote AM technologies.

III. “Rising Tide” Moments in AM
Key breakthroughs have propelled AM into the spotlight:

• Post-Recession Media Boom (Early 2010s): A surge in 3D printing coverage raised public awareness.
• GE Leap Nozzle (2011–2012): GE’s use of metal AM for a jet engine nozzle proved the technology’s real-world viability, especially for end-use parts. It shifted the narrative from cost savings to transformational manufacturing and spurred major investments.
• HP’s Market Entry: HP’s involvement brought credibility and scale, boosting global adoption.
• Obama’s 2013 State of the Union: Mentioning “America Makes” elevated AM to national attention.

IV. Plastics vs. Metals and What’s Next
While plastics dominate in volume, metal AM has seen faster ROI-driven growth, especially in low-volume, high-value applications. The next leap is expected within five years, driven by advances in materials, surface finish, and repeatability.

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This podcast episode, "The Recurring Cycles of Additive Manufacturing," from AM Insider, explores the challenges and cyclical nature of additive manufacturing adoption

Key takeaways include:

1. The "David and Goliath" Problem: The industry faces the ongoing challenge of differentiating between expensive industrial 3D printers (costing $30,000 to hundreds of thousands) and affordable prosumer/consumer models ($500-$2,000) This creates a need to educate customers and manage their expectations, as many are attracted by price but lack understanding of capabilities.
2. Recurring Industry Cycles: Challenges like customer education and market confusion are cyclical, reappearing with every "quantum jump in either a capability or a price". While the volume of inquiries surged with cheaper printers, the industry now benefits from more experienced salespeople adept at product differentiation.
3. Historical Context and Prognostications:
   • Early 3D printing (rapid prototyping) was first showcased at CAD/CAM shows like Autofact in the 1990s. Its primary purpose was to validate designs from expensive CAD systems, as advanced simulation tools were not yet common.
   • Many "prognostications" about additive manufacturing's future (e.g., printing an oven knob at home) that circulated in the 90s' B2B space are now being reiterated by new entrants in the consumer market, often unaware of the industry's history. This influx of publicity, though creating "extra work" for established professional companies due to unqualified calls, ultimately helps grow the industry by introducing more people to the concept of additive manufacturing.
4. Future Evolution: The next significant "quantum leap" in the industry is expected to be in the capability of affordable machines, not just further price reduction. This could involve machines combining smooth surface finish, color, and mechanical performance at lower price points, alongside the development of useful content that leverages these advanced capabilities. The goal is to evolve technologies for better output in profitable hardware.