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This episode features an interview with Rajeev Kulkarni, a seasoned professional in the additive manufacturing industry, who shares his extensive experience and insights into the history, evolution, and future of 3D printing. Rajeev discusses his early contributions to the field, including the invention of support generation for SLA and the creation of the STL file format, highlighting the collaborative effort required for innovation and the importance of focusing on problem-solving and applications rather than just technology. He also offers advice for newcomers and executives in the industry, emphasizing the need to view 3D printing as a manufacturing technology and to integrate it within a broader digital ecosystem rather than positioning it against traditional methods. The conversation touches upon the impact of AI and the rewarding aspects of 3D printing, particularly in healthcare.

1. Humble and Challenging Beginnings: 3D printing began in the early 1990s from a state of "nothing," facing significant challenges such as a lack of 3D CAD design, expensive software, and the absence of standard formats, which led to the creation of the STL format. Computers were also slow, sometimes taking overnight to slice a file.
2. Evolving Industry Vision: Initial visions for 3D printing centered on accelerated product development, toolless manufacturing, and customization/one-off production. The concept of on-demand and distributed manufacturing emerged later as the technology evolved and customers presented these possibilities.
3. Innovation Through Collaboration and Iteration: The industry's rapid progress from creating the first 3D printers to establishing business models in industries like hearing aids and jewelry within 8-10 years was a multidisciplinary, cross-functional, and collaborative effort. Success hinged on being nimble and iterative, as customers often did not know what to ask for in a disruptive technology. Rajeev Kulkarni himself invented support generation for Stereolithography (SLA), drawing inspiration from electric pole designs.
4. Focus on Applications and Solutions, Not Just Technology: The core principle for success is that "technology is the cost and the application is the revenue". Focusing on specific applications and customer solutions that address real-world problems is paramount, as demonstrated by the long-term success in sectors like dental and hearing aids.
5. No Single "Killer App" or "Inflection Point": The industry has not experienced a singular "inflection point" or "killer app." Instead, successful applications like aligners, hearing aids, dental, and jewelry have achieved significant penetration through a "grind" that takes years or decades to replace complex workflows and achieve perfection.
6. "Manufacturing," Not "Printing": A significant disservice to the industry is referring to it as "printing" instead of "manufacturing." Executives and professionals must understand that replacing or enhancing manufacturing workflows is a complex undertaking, not a simple printing task, and requires a manufacturing-oriented mindset to succeed.
7. Complementary, Not Replacement, Approach: Positioning 3D printing against traditional manufacturing is often the "wrong approach." The real value of 3D printing lies in enhancing and complementing traditional methods, such as accelerating design cycles, producing complex internal features, or consolidating multiple part assemblies.
8. The Importance of the Entire Ecosystem: The success of 3D printing extends far beyond the printer itself, encompassing a vast ecosystem including design software, reverse engineering, pre-processing, materials, post-processi

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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.