Solutionology Podcast: Recent Episodes
Brian Douglass, DI Labs COO & Carl Douglass P.E., DI Labs CEO
Welcome to Solutionology! This podcast was created by DI Labs, an additive manufacturing and industrial 3D printing service bureau built by product development and manufacturing engineers. Our hosts, DI Labs Co-Founders Brian and Carl Douglass, are “solutionologists” who solve problems and create new opportunities for customers by leveraging their diverse and powerful fleet of cutting-edge additive technologies. They'll be using this platform to share a wide range of the most challenging product development and manufacturing problems they are tackling these days using additive technology and a mindset of solutionology.
Our Solutionology podcast shares behind-the-scenes stories of projects and problem-solving using a digital mindset. In Episode #25, Carl Douglass, DI Lab CEO, and Brian Douglass, DI Labs COO, have an in-depth discussion about quality with Hannah Kinder, DI Labs Production Manager.
Quality can be a touchy subject in additive manufacturing because it often seems ambiguous and expectations can be wildly different between each client and project. Brian states that quality, which is considered a deliverable, and a digital mindset, which is a state of constant transition, can feel like oil & water. That’s because when people think of quality, they think of standardization and repeatability - not constant change.
As the industry continues to evolve and mature, having a digital mindset is critical to our success, especially when it comes to quality. DI Labs is in a constant state of transition to new levels of performance, capabilities and standards of quality. As Hannah said in the wrap-up, change is inevitable especially if you want to be better. And we always do.
Listen to the full episode to learn more.
Chapters & Episode Topics:
00:00 Intro
01:02 Structure of quality
01:27 Digital mindset and quality - oil and water
03:15 Quality is a tradeoff
04:06 Definitions of quality
05:50 Culture supports quality
07:51 Our ISO9001 onboarding process
11:53 Understanding client expectations
15:45 How quality drives scrap rates
18:59 Scrap from 10-25%
19:11 Current improvements
More Solutionology Stories Podcast Episodes: https://dilabs.cc/podcast/
What is a digital mindset, and how does it add value to the product development, design, management & manufacturing process?
In Episode #24 of the Solutionology Podcast Carl Douglass, P.E. and Brian Douglass from DI Labs dig into this topic.
Brian starts by providing a simple definition of a digital mindset from the DI Labs perspective. "A digital mindset is a way for us to stay flexible throughout a process or project... so that we're not locked into a preconceived bias... it's the ability to create rapid changes and store them in a quick and lightweight format like digital..."
Carl then quotes an article from the Harvard Business Review by Tsedal Neeley and Paul Leonardi called, "*Developing a Digital Mindset." Under the section "Change as a Constant" he reads:
According to change management theory, organizations move from a current state to a transitional state and then on to a future state... In a digitally driven world, however, there is no endpoint to the transitional phase.
This excerpt resonated with Brian and Carl due to the never-ending state of transition, which is a mindset they embrace. Listen to the full episode to hear more.
*Find the full article* here.**
At DI Labs, we've been applying a digital mindset for a long time and now help clients build it into their programs and products, leading us to what's next! Stay tuned to learn more about the custom-designed Solutionology Sessions we'll be offering to companies interested in mobilizing their teams with a digital mindset.
More about DI Labs: dilabs.cc
Find more episodes of the Solutionology Podcast on YouTube.
What does it mean to have a digital mindset and how does it open up possibilities in product development and manufacturing? On this episode of the Solutionology Podcast, Carl and Brian share DI Lab’s journey in creating a consumer product line that has grown exponentially by leveraging the power of a digital mindset and manufacturing process. It allowed us to approach the market without the constraints of traditional manufacturing, accelerate our product launch, and give us a competitive edge through customization.
We started by solving a very specific problem which quickly revealed unexpected market demand and an opportunity to create a wide spectrum of products and variations. Our technology tools include the HP Multi Jet Fusion for printing and the AMT PostPro for finishing.
00:00 Intro
00:34 Welcome - we’re in a different space
01:13 Product owners and manufacturers
01:51 Product development & testing
02:36 Solving a problem
05:21 Mass customization workflow
07:17 Segmenting the market for variations
08:57 Maximizing value with a digital mindset
09:56 The tools needed
10:57 What we’ve learned
Recently, Carl and Brian Douglass were guest experts on a Webinar hosted by MasterGraphics and Mindfire. We are posting this as an episode of the Solutionology Podcast with their permission. Access the original posting here.
Could you elevate your Approach with a Solid Plan from the Experts?
Challenge the status quo by asking yourself: Is your current additive manufacturing plan truly optimized, and how can you elevate it to new heights of success?
Prepare for enlightening insights as our experts share their valuable knowledge. You'll hear from 4 expert panelists:
- Carl Douglass, CEO, DI Labs
- Brian Douglass, COO, DI Labs
- David Rosendahl, President & Co-Founder, MindFire Inc
- Kevin Carr, President, MasterGraphics
In this session, our panelists will analyze and exchange insights on:
- How embracing Additive Manufacturing can reshape your product development approach, fostering agility and sparking creative ingenuity.
- Why having a structured process for product development through Additive Manufacturing is not just advantageous, but essential.
- How aligning your additive manufacturing strategies with your business goals can drive growth, boost efficiency, and amplify your competitive edge.
- Whether you're a business owner, product manager, or industry professional, this webinar offers valuable insights and practical strategies for anyone seeking to enhance their additive manufacturing prowess.
In this mini-episode of the Solutionology Podcast, we’re addressing some of the most common questions we get about volume production using additive manufacturing. In fact, these questions were the driving force behind a technical presentation that Carl Douglass, DI Labs CEO, created and will be delivering at the Medical Device and Manufacturing tradeshow in Minneapolis. We’re just getting warmed up and hope to see you there!
Common questions about volume production with additive manufacturing:
- What types of applications and projects are the right fit?
- What reasons should drive the decision to use additive?
- What reasons should drive the decision NOT to use additive?
- What does the production part approval (PPAP) process look like?
Takeaways from Carl’s presentation:
- To successfully leverage additive for production, build it in early
- High-tolerance parts are possible
- Additive shouldn’t be considered the end-all-be-all
- Additive can be a superpower if used in the right applications
Related Content:
- MD&M technical presentation details
- Article in "Plastics Today" about the presentation
Chapters & Topics:
00:00 Intro
00:15 Welcome
00:40 MD&M presentation takeaways
02:27 Go & yield applications for additive
04:51 Organizational limitations
05:34 Need a champion and stakeholders
08:28 Keys for successful production
09:27 Developing a production part approval process
11:37 Validating biocompatibility for medical device
13:35 Biggest shortcomings in preparing for additive
14:06 See you at MD&M
More about DI Labs:
https://dilabs.cc/
We’re back with a favorite client and good friend, Mike Van Staagen, owner of Van Staagen Design and VP of Advanced Design and Development for Cirrus Aircraft.
In this episode, Mike talks about working with a company to design the internal body of a very specialized camera about the size of a soda can. He explains how leveraging the DI Labs Multi-Jet Fusion (MJF) capabilities for final production allowed him to drive complexity into his final design. His solution included a single printed part, which he describes as “impossible,” that held over 20 components together and went through multiple iterations to add new features such as snaps, wire runs, and clips. Mike calls MJF technology "a solution that can grow with you."
More about DI Labs.
Watch all of our Solutionology Podcast Episodes on YouTube.
Related Content:
- Ep #18 | The Impact of Rapid Modeling at Full Scale: Cirrus Fuselage
- Ep #19 | Insights from a 30-Year Career in Product Design w/ Mike Van Staagen
In this special episode, we got 30 years of wisdom from renowned product and aviation designer, Mike Van Staagen. Mike is extremely passion about sharing what he's learned on his professional journey which started with architecture and led to his current position as VP of Advanced Design and Development for Cirrus Aircraft.
Among Mike's many career achievements, he helped to envision, design and lead teams for the best-selling Cirrus SR20/22 aircraft. He was also the creator and driving force behind the Cirrus SF50 Vision personal jet.
Here's a snapshot of the insightful and powerful points Mike makes in this episode. If you're looking for inspiration, take a listen!
Episode Topics:00:00 Intro
01:41 Thinking like an architect changes your perspective
06:25 If a picture is worth 1,000 words, then models are worth 1,000 pictures
07:33 Making bold moves can create bold results
18:17 A design is never, ever finished
20:11 Accidental discovery is a superpower, so create opportunities for it to happen
25:56 Models and prototypes are the best possible ambassador for your design
32:14 Polygon modelers are easy to manipulate and like having digital clay
Watch all of our Solutionology Podcast Episodes on YouTube:
• Solutionology Podcast
More about DI Labs:
https://dilabs.cc/
Don’t miss this conversation with a favorite client and good friend, Mike Van Staagen. Mike is a renowned designer of aircraft, mobility solutions, products of all sorts, and a manufacturing engineer with an award-winning 30-year career. He currently serves as the VP of Advanced Design and Development for Cirrus Aircraft while also operating his own design firm. Mike's many accolades include helping to envision, design and lead teams for the best-selling Cirrus SR20/22 aircraft. He was also the creator and driving force behind the Cirrus SF50 Vision personal jet.
In this episode, Mike explains the daunting challenge he brought to DI Labs during the design phase of a new Cirrus aircraft project. Our solution, which was delivered to Cirrus in just 30 days, was a full-scale fuselage prototype created using additive manufacturing. We printed over 130 thin-walled panels and developed a proprietary system of mechanical joints and assembly to build a 10' x 4.5' model that became the ambassador of Mike’s new design concept.
Dimensional accuracy was critical in this project which is why it is a perfect example of Mike's theory that 1/8 of an inch can make all the difference.
00:00
01:07 Welcome and introduction
03:32 Accomplishments at Cirrus
04:30 Ideas behind the Cirrus SR20 & SR22
07:14 Creating the best passenger experience
08:07 Hand constructed full-scale fuselage of the vision jet
11:12 The ⅛’s of an inch difference
12:11 3D printed full-scale fuselage shows ⅛’s of an inch
14:22 An accomplishment
See this project profile on our website: https://dilabs.cc/portfolio-item/full...
Watch all the episodes on YouTube: Solutionology Podcast
Learn more about DI Labs: https://dilabs.cc/
This episode of the Solutionology podcast is unlike any other we've done. Our guest is Todd Buness, the CFO and President of Prinsco, a long standing product development client of DI Labs. In this conversation we do a deep dive into the business and finance side of product innovation from his perspective. It's a topic that takes us away from the technical details of additive manufacturing and highlights how the benefits of additive support innovation with speed, rapid learning, and flexibility to iterate.
Todd is a great storyteller and shares specific examples of how this has played out in companies he's worked for such as Cargill, Heraeus, and Prinsco. He describes himself as a "manufacturing guy" and not a typical CFO because of his strategic focus on bringing together the functional units of an organization to drive success. He talks about understanding customer needs, designing the right thing, getting something into customer hands as soon as possible for feedback, getting to market quickly to start a revenue stream and building a partner relationship with clients. It's a long-term, solutions-based way of thinking that is very aligned with our approach at DI Labs which is why these types of conversations are so much fun for us! Enjoy!
00:00 Intro
05:02 Inside the episode
07:42 Bringing together engineering, manufacturing and sales
08:30 Heraeus contract manufacturing approach
10:21 Medical component example
14:18 Not a typical finance guy
15:35 Shifting the customer perspective at Cargill
16:49 First ever customer solutions strategy
18:25 Converting a commodity business into a solution model
19:36 Beer barley examples
22:21 Helping customers shift their thinking
25:57 Story of shifting from commodity vs solution customers
29:53 Scarcity mindset to opportunity mindset
31:55 Enlarging the pie vs getting the lowest price
33:04 Classifying customers to service them correctly
34:19 Challenges of managing a program
37:30 Advice to your younger self
39:46 Getting the commitment to get programs launched
https://dilabs.cc/
Carl & Brian walk through examples of how they’ve used industrial 3D printing (additive manufacturing) to drive innovation in projects using low pressure molding methods such as thermoforming. You’ll see examples where traditional molds were modified with 3D printed components in order to enhance features and test design changes during real time production. When additive is used this way and in this part of the process, it can help product development teams fuel innovation and make better, more strategic decisions.
https://dilabs.cc/
00:00 Intro
03:33 Additive isn’t always the best solution
04:05 Early thermoforming mold
05:26 Glass bead reinforced nylon 12
07:13 Traditional manufacturing
10:48 Different testing approaches
11:45 Product changes in real time– modified molds
12:19 Scheduling production down time
15:30 Balancing desired outcome with economics
16:14 Our approach– understanding the whole picture
17:14 What validating thermoforming can achieve
19:32 Demonstrating use of additively produced components
21:46 Thermoforming in process demonstration
23:21 Improve product with existing tooling
24:24 Inserts attached to the mold to change geometries in real time
30:24 Marrying technologies to drive a decision
32:13 HP Multi Jet Fusion is the primary resource
35:40 Change is part of our
Do you have experience with ultra-high-performance PEEK materials? Come from an industrial application with harsh chemical & thermal conditions? Robert McKay & Silvia Berretta of Victrex have extensive experience with PEEK and have been instrumental in launching PAEK, an ultra-high-performance option to PEEK with increased printability & more flexible processing window. In fact, VictrexAM™ 200 PAEK is now a Stratasys validated material. We've experienced challenges printing with PEEK & believe the processing ease & flexibility offered by PAEK could vastly accelerate the adoption of additive across applications like aerospace, defense, medical, heavy industrial & electronics. Learn how PAEK is an additive manufacturing superhero!
00:00 Intro
01:52 PEEK material & challenges
05:26 Intro to Victrex, inventor of PEEK
06:04 PAEK is the true superhero
06:30 Meet Robert McKay & Silvia Berretta
09:33 Victrex & PEEK designed for injection molding
10:35 Evidence of PEEK’s use worldwide
11:25 Victrex manufacturing
12:20 The AM world in Victrex
13:26 PEEK support group?
14:07 PAEK pulled by trends
15:50 Relationship between PEEK & PAEK
16:21 Misconceptions of PAEK
18:42 PAEK molecular differences & crystallization speed
21:39 PAEK lower viscosity & wider processing window
23:00 PAEK soluble supports & a sweet spot of crystallization
26:25 Victrex & the Stratasys OpenAM program
28:55 OpenAM Beta & first part using AM 200 PAEK
34:36 Acceptance and success of PAEK
36:47 PAEK qualified for aerospace flight uses
38:28 Defining certifications to achieve
39:36 Higher chemical resistance
45:34 Reinforcement additives
48:25 Requests for fiber-filled filament
49:45 Specifying materials for additive
51:21 Drivers of carbon fiber
53:02 Advice about exploring PAEK
55:22 Confidence to align PAEK with PEEK applications
PAEK at DI Labs
There's a lot of overselling and hype in the additive industry right now that's not founded in reality. In this excerpt from the Solutionology Podcast Episode #13, we talk about this trend toward transactional, short-term thinking. On the flip side, we share how embracing discomfort and taking ownership of client projects is built into the DI Labs culture. Hear examples of when our engineering-first approach has driven us to take risks, push beyond client expectations, and do things differently. Ideally, our client relationships become a collaborative push and pull where both sides are challenged to see past short-term wins and create strategic, long-term solutions.
Find the full episode on YouTube!
Learn more: https://dilabs.cc
As a customer, have you ever been disappointed by a company's willingness to honor promises? Does it feel like their commitment stops when their profitability stops?
We've been on the receiving end of this problem recently, which has only strengthened our resolve to deliver on promises we make to customers, no matter what. DI Labs is an engineering-first additive provider committed to solving problems the right way vs making sales the quick way.
That's the topic of this excerpt from episode #13 of the Solutionology podcast about the 5 Pain Points of Additive. What's been your experience with making promises vs delivering on promises?
When companies promote quality, what do they really mean? In this excerpt from the Solutionology Podcast 13, DI Labs Co-founders Carl and Brian Douglass dive into the topic of quality and the role it plays in meeting customer expectations.
In additive manufacturing, quality is tied to dimensional accuracy, tolerance control, consistency, and performance. It’s about understanding and setting expectations on the front end, then building in process controls through the entire production cycle to ensure that every single part meets the quality standard required for that client, application and performance level. Learn how our 3D scanning CMM (Computerized Measuring Machine) along with our digital workflow and hands-on inspection process give DI Labs the ability to ensure quality on an entirely new level.
https://dilabs.cc/
There's a high degree of pricing and quality variability in the market from additive manufacturing service providers. In this excerpt from the Solutionology Podcast Episode 13, Carl and Brian talk about the difference in approach between service providers offering cheap parts and companies like ours focusing on achieving the highest quality possible.
It's a mindset shift that starts with packing density when preparing parts for printing. Packing a build vs designing a build is an important distinction and can have a tremendous impact on quality. It's a manufacturing variable in additive that can be compared to controlling speed and cooling profiles in injection molding to ensure dimensional accuracy.
Tune in to learn more!
More about DI Labs: https://dilabs.cc/
Many additive adopters are buying new printers with the expectation that they're "plug & play." In this excerpt from the Solutionology Podcast Episode #13, Brian and Carl dive into the topic of what it really takes to successfully onboard new additive technologies and build a digital workflow to support quality and consistency. Additive is an industrial manufacturing process just like injection molding with a wide spectrum of variables to manage, many of which come as a surprise to new adopters.
In this episode, we brought our great friend and team member, Justin Hildebrandt, into the podcast studio during his annual stint at DI Labs. You see, Justin has spent two weeks a year for the past ten years as a DI Labs Solutionologist.
Why only two weeks? Because the rest of the year he's a highly skilled pilot as part of his family's agricultural aviation business in Colorado. Justin is a lifelong friend of Brian, Carl, and Sean Douglass. He's also an avid learner and a passionate problem solver, which is why he spends time at DI Labs each year doing everything from repairing complex technologies, to building dye stations, to installing robots.
During our discussion, Justin shares his unique perspective on our Solutionology culture. He describes witnessing significant, generational technology changes over the years paired with an incredible consistency in focus and customer-centered problem-solving.
1:10 Welcome
2:27 Justin’s background
3:48 Crop dusting is like golf
4:46 An introduction to precision
6:06 Being an aircraft engine mechanic
7:24 Not a fit for the auto industry
7:59 Hunger to learn & high precision
9:51 Two weeks a year for 10 years
10:48 Modeling solutionology
11:31 Generational change and consistency
13:14 Justin's definition of solutionology
15:25 Advice to customers or team members
16:27 Always hungry to do something new or better
17:19 Evolution of the way we think
18:31 Why DI Labs exists
20:07 You make us better
Learn more: https://dilabs.cc
This Solutionology episode is inspired by our work serving the medical device industry, which makes up over 50% of our business. We dig into the details of medical device applications but the takeaways apply to product innovation in many high-end applications where a manufacturing process that supports tight tolerances, exacting quality, unique geometries, design flexibility, and sealed surfaces is absolutely critical to success.
You'll hear our take on the ways additive manufacturing currently serves medical device applications and the opportunities it has to create transformational innovation when considered earlier in product development cycles. It's an important topic as we prepare to attend the Medical Design & Manufacturing (MD&M) Tradeshow in California which will initiate all kinds of problem-solving and exploratory conversations about additive manufacturing with medical device innovators.
Find us at MD&M:
https://www.linkedin.com/events/md-mwest7022977598309748737/
Schedule a 1:1 engineering consult with Carl Douglass at MD&M:
https://calendly.com/dilabs/am-eng-consult
Episode Topics:
01:08 Welcome
02:13 Phases of medical device development
03:14 Driving change toward additive
03:32 Materials
04:11 Functional aspects
05:15 Process controls and traceability
06:12 The speed of evolving technology
06:54 Types of medical device we can support
07:29 Cardiovascular applications
07:54 Enclosures for medical device components
08:15 Internal structures for medical device
08:54 High mix low volume
09:19 Applications in the operating room
09:38 Analogue or digital
10:50 Entire system - greatest advancement for additive
12:11 Benchtop trials and iterate in weeks instead of months
12:24 Design validation and clinical trials in months rather than years
12:42 Supporting the switch from traditional manufacturing to AM
13:40 Opportunities in concept phase for DFAM and components
14:19 Design validation - adapting legacy design to AM
15:22 Early-stage opportunities vs late-stage opportunities
16:34 Ground zero allows for innovation and timeline advancement
17:13 Supporting transformational innovation
18:04 Reducing timelines is our focus
18:20 Full-color printing for enclosures can build confidence
20:10 Enhancing the user experience
20:50 Parts we'll have at MD&M
21:42 Functional anatomical models
23:46 Consistently high tolerance production
24:26 Visual CMM for dimensional analysis and quality control
25:59 Preproduction analysis & predictive modeling
27:26 Misconceptions about what it takes for consistency
28:34 Quality is a core foundation
30:14 Bring us your pain points at MD&M - connect with Carl
Find us at MD&M:
https://www.linkedin.com/events/md-mwest7022977598309748737/
Schedule a 1:1 engineering consult with Carl Douglass at MD&M:
https://calendly.com/dilabs/am-eng-consult
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In this episode of the Solutionology Podcast, we talk with Serah Peterson, engineer and project lead at PHYTEC America, and learn about her experience working with DI Labs to solve a problem so many innovative companies face: bridging the gap between a new product and its final application so customers can connect more deeply with it, see its potential and appreciate its value.
PHYTEC is an industry-leading provider and integrator of System on Modules (SOMs) which are core components of an embedded processing system. In 2022, they developed a software and chipset for EV chargers that included Texas Instrument components. When they contacted DI Labs, they had been displaying their new product in a fabricated acrylic housing that was functional but not at all reflective of the industry they wanted to serve.
Join us to learn how Serah discovered additive as a potential solution and how DI Labs was able to design and manufacture an EV charger housing that would change the game for the launch of PHYTEC's innovative new product.
The final PHYTEC solution delivered by DI Labs included product design, prototyping, and low-volume production using HP Multi Jet Fusion technology, Nylon PA12 material, Vapor Smooth finishing, and dyeing.
Watch the full episode on YouTube!
https://youtu.be/Ppak_YUXBb4
Episode Topics
01:12 Welcome, PHYTEC
02:53 Project details
03:46 EV charger reference design: Rev 0
06:28 Framing the problem: the fish tank
08:43 New product development process
09:26 Initial sketches and translating
10:57 You don't know what you don't know
11:41 How DI Labs did it
16:06 Working with electronic files
16:49 Final design
17:20 A housing to connect with customers
19:24 Learning about SOMs
21:30 PHYTEC's customer base
23:07 Saving years getting to market
24:10 Enabler for the advancement of technology
25:02 Solving supply chain issues
25:54 PHYTEC accelerates action
27:40 Appreciating embedded systems
28:04 Serah's journey to additive
29:22 "We have to injection mold, right?"
33:00 Parallels of DI Labs & PHYTEC
35:56 Bridging the gap
More about DI Labs: https://dilabs.cc
There's lots of buzz about mass customization, but how do you actually apply it from a product development and manufacturing standpoint?
In this episode, we dive into the details of our two-year journey using mass customization to develop our own direct-to-consumer brand called Threedom. It's a behind-the-scenes conversation about the challenges we faced creating the complex digital workflow necessary to scale one product design to nine products and over 30,000 SKUs. We talk about the opportunity we discovered to build an ever-expanding platform of unique products that connect with customers in a whole new way and you'll also get ideas about how to apply the concept of mass customization to functional or industrial parts.
Watch the full episode on YouTube: https://youtu.be/ufsomEV1vbU
Episode Topics
01:03 Welcome
02:35 Challenge of injection molding
04:18 Speed to market and increased market share
05:19 Difference in capital investment
06:00 Uses of mass customization
07:35 Visual personalization
09:04 Serving unique market segments
10:01 Business model innovation
10:50 Our use case for mass customization
14:50 Nine products
15:15 38,500 digital files for 9 products
17:24 Getting real-time feedback from customers
19:55 Initial vision for tailored products
20:32 Managing SKUs
21:28 Building on demand & inventory management
22:00 What we've learned
23:21 Time investment in digital workflow
24:24 It's really hard
25:00 Competitive products
26:16 One design became a product platform
26:54 Applying it to functional or industrial parts
28:28 Version control
30:19 Surface textures
31:39 Manufacturing process to manage complexity
34:25 Defining key constraints
35:01 Multi Jet Fusion
36:01 Lessons after 2 years
37:47 Apply our experience to your project
38:52 Business model innovation vs part costs
39:14 Perceived value of the product
40:58 Powerful brand that connects with consumers
Learn more about Threedom: https://dilabs.cc/portfolio-item/threedom/
Learn more about DI Labs: https://dilabs.cc/
On this episode, we address an edgy topic that has caused more than a little frustration among customers and industry peers - “Additive Hype vs. Additive Reality.” To gain a broader perspective, we invited Kyle Harvey, Additive Manufacturing Business Unit Manager at Extol, to join us. He’s a self-proclaimed “recovering engineer” and outspoken educator in the additive space. Extol is a manufacturing technology company that provides plastic assembly technology, custom automation, and engineering services.
Don’t miss this conversation! Here are the timestamped highlights:
3:00
GUEST INTRO: Kyle introduces Extol and how they are working to shift the focus from parts to products
5:52
HYPE: Additive offers high value within a business for functional prototypes and end-use production (i.e., it’s easy)
REALITY: No one offers a game plan for making the value real (i.e., it’s difficult)
9:00
HYPE: You can buy a printer, push print, and catch the money as it prints out (i.e., it’s plug & play)
REALITY: The additive adoption process is full of hidden costs for design, downtime and scrap (i.e., it’s expensive)
19:11
HYPE: The value of additive manufacturing is low-cost parts (i.e. it saves money)
REALITY: Companies are offering below-cost pricing which is a race to the bottom (i.e., low cost = low quality)
22:52
HYPE: The fall of Fast Radius proves the additive industry bubble is bursting (i.e., it’s not as valuable as promised)
REALITY: Additive has long-term value when done sustainably, but we’re seeing business model failures driven by unreal expectations. (i.e., success requires a wholistic approach)
34:40
HYPE: Printer manufacturers focused on selling “all the latest” hardware will drive success for our industry (i.e., more technology = more success)
REALITY: Education about successful additive adoption must be pushed upstream to equipment suppliers and downstream to additive customers. (i.e., success can’t happen without education)
38:38
OUR ADVICE: Kyle, Carl & Brian offer words of advice to those getting started with additive
Watch the full episode on YouTube! https://youtu.be/ImahP5gcGYE
More about DI Labs: https://dilabs.cc/
One of the most common questions we get about additive capabilities is: how do you achieve and manage tight tolerances? Those asking are usually in mission critical applications like medical device, aerospace, or aviation where extremely high levels of quality are required to meet exacting tolerance specifications and performance needs.
Our quality assurance and control process now includes a non-contact, high-accuracy, 3D scanning coordinate measuring machine (CMM). It's an incredible technology that alleviates our dependence on traditional or manual measuring tools which are not effective for parts with nonstandard geometric features and are not scalable for full production. Our CMM measures parts from all directions, capturing millions of data points that allow us to compare 360° scans directly to CAD data to detect deviations and defects or do a wear analysis before and after use of a part. This new tool greatly expands and supports our ability to serve mission critical applications with additive manufacturing.
Watch the full episode on YouTube!
https://youtu.be/4eCNyp-gnTg
Episode Topics
01:00 Most common question
01:35 What we're doing to manage tolerances
02:01 Managing tolerances for production
02:25 Starts with onboarding a project
05:24 Tolerance stack up for additive
05:56 CMM allows us to capture data
07:14 Production runs with dimensional traceability
08:32 Mitigating the risks
10:02 Collecting & analyzing the data
10:40 How we've fine-tuned our processes
11:48 Role CMM plays in PPAP
13:14 Quality is not sexy
13:48 Variations that exist throughout a build
15:02 Our focus is quality
15:46 Pushing the technology as far as it can be pushed
16:42 Aspects of achieving tight tolerances
18:02 Quality is a piece of our culture
18:55 Project that pushed us to invest in the technology
22:48 Continuing to push the boundaries
More about DI Labs: http://www.dilabs.cc
In this episode we share some exciting news about the latest advancements in additive solutions at DI Labs. We've added Ultra White to our core capabilities powered by HP’s 5420W, a new generation of Multi Jet Fusion (MJF) technology that is currently being launched at FormNext in Germany! We’re proud to be an HP beta partner and the first in North America to run this new technology and help get it to market.
The addition of Ultra White gives DI Labs another valuable tool in our toolbox for high-end applications like medical device and automotive where white parts are an essential aesthetic.
Watch and listen to see some of the Ultra White parts we've printed, several of which are currently on display at the HP booth at FormNext, and learn more about the strategic advantages of this new solution.
Full press release: https://dilabs.cc/di-labs-adds-ultra-white-printing-to-core-capabilities/
More about Ultra White: https://dilabs.cc/ultra-white/
Watch the full episode on YouTube: https://youtu.be/jvZB7-eB7Qs
Episode Topics
00:34 Welcome & big news
00:48 What is Ultra White
01:31 Selected for HP Beta
03:30 What is the 5420W
03:56 Legacy of white parts
04:29 Parts so far & advantages
05:31 Compared to SLS
06:35 Resolution to support our texturizing
08:46 Texture for ergonomics
09:17 Benefits to medical industry
10:10 Surface treatment maintains white color
11:12 Color uniformity
11:44 Parts on table - surface quality
12:48 Dyeing creates brilliant colors
13:42 Excited to be an HP partner
14:26 MJF scales well
14:57 Our parts at FormNext
15:59 Contact us for Ultra White
Welcome to the "Free the Fortus" Podcast (now called the Solutionology Podcast), fueled by the Stratasys #OpenAM Validated Materials Beta underway at DI Labs. We're a Stratasys global launch partner for this groundbreaking program that will free the Fortus 450MC of its closed system limitations and unlock the potential of the industry's most powerful FDM platform.
Matt Howlett, the President/Founder and Chief Innovation Officer at 3DXTECH, is a leader in material development for fused filament printers. He started the company in 2014 with specialty material formulations that focus on functionality. Their goal is to make the most innovative filaments on the market – targeting difficult end-use applications where functionality is king.
The Stratasys #OpenAM Beta gives DI Labs unprecedented freedom to modify the process settings and other adjustments necessary to successfully run a wide range of new, highly engineered materials such as PAEK, PEKK and Glass Filled Nylon 6/66. It’s never been done and we’re confident that the outcome will change what’s possible for additive manufacturing in service of high-performance industries like medical device, aerospace, electronics, industrial and automotive industries.
READ THE FULL STORY: https://dilabs.cc/di-labs-is-first-in…
Watch the full episode on YouTube: https://youtu.be/Ulzirh1QKqE
Episode Topics
00:29 Welcome back
01:00 Update on Week One Beta Program
02:11 Introducing Matt Howlett, 3DXTECH
04:06 Started business in 2014
06:36 Factors driving printer innovation
08:23 Opening opportunities to run new materials
10:55 Running the 450 with new materials
13:25 3DXTECH material performance
14:20 Carbon-fiber reinforced materials
15:31 New applications for newly developed materials
19:58 Pipeline & process for material development
23:36 Opportunities for new materials
25:36 Vertical markets for PEEK
27:31 Product development with new materials
29:12 Solving problems together
29:29 Great work in PEEK
30:27 More business with 3DXTECH
LEARN MORE ABOUT DI LABS: https://dilabs.cc
DI Labs is always seeking opportunities to be on the cutting edge and push boundaries. In this episode, we share some exciting news about the work we've been doing with white nylon parts. We've got some beautiful samples and give you a preview of what's to come with this latest advancement in additive manufacturing which will be another tool in our toolbox to serve high-end markets like medical and automotive where white is an essential aesthetic.
Towards the end, you'll also hear how the three brothers and owners of DI Labs define "solutionology" in their roles at the company.
Watch the full episode on YouTube!
https://youtu.be/ZU2DK5AkaW4
Episode Topics
00:35 Welcome
01:17 Change in podcast
01:48 White nylon parts
02:44 Another new project & technology
03:34 Why not SLS
04:45 White for medical device
06:03 Onboarding new technology
06:38 It takes a team
08:12 Expanding the podcast
09:15 Being a solutionologist
LEARN MORE ABOUT DI LABS: https://dilabs.cc
This episode marks an important transition! The DI Labs podcast was previously built around the Stratasys OpenAM beta running at our facility. But as die-hard problem solvers, we're broadening the scope. It's been renamed the Solutionology Podcast, allowing us to interview all types of guests and share our problem-solving perspective on a wide variety of topics such as innovating for unique applications, bringing on new technologies, optimizing for new materials, and growing our business. Thanks for joining us on the journey!
In this conversation, the three Douglass brothers, who are owners of the business, provide an update on the "Free the Fortus" OpenAM beta. That leads them into a much deeper discussion about just what it takes to onboard new materials and new technologies. Enjoy!
Watch the full episode on YouTube: https://youtu.be/XlBtjLJx1d8
Episode Topics
00:34 Welcome
00:55 Intro to the Douglass brothers
05:01 Free the Fortus update
08:15. Onboarding 5 new materials
09:40. Revisions to get to a new profile
12:33 High-temperature, higher-end materials
13:08 PEEK is the most challenging
13:51 Data drives the problem solving
17:48 The fail-fast method
18:30 It's anything but easy
19:31 We're pushing the hardware and software
20:20 Materials get validated before production
20:24 Transitioning podcast from Free the Fortus
22:35 It's about problem-solving
23:26 Future topics
LEARN MORE ABOUT DI LABS: https://dilabs.cc
Welcome to the "Free the Fortus" Podcast (now called the Solutionology Podcast), fueled by the Stratasys #OpenAM Validated Materials Beta underway at DI Labs. We're a Stratasys global launch partner for this groundbreaking program that will free the Fortus 450MC of its closed system limitations and unlock the potential of the industry's most powerful FDM platform. The Stratasys #OpenAM Beta will give DI Labs unprecedented freedom to modify the process settings and other adjustments necessary to successfully run new, highly engineered materials such as PAEK, PEKK and Glass Filled Nylon 6/66. It’s never been done and we’re confident that the outcome will change what’s possible for additive manufacturing in service of high-performance industries like medical device, aerospace, electronics, industrial and automotive industries.
Watch the full episode on YouTube!
https://youtu.be/2zAdVwzXGSk
Our first guest is Tom Leach, Commercial Leader of Industrial Business Units at Stratasys. He explains why Stratasys is making this bold moving to OpenAM and shares his excitement for what's to come with the beta.
Future episodes will explore:
- How highly engineered materials and additive offer new options for customers of traditional manufacturing
- The unique challenges of running highly engineered materials
- Real-world beta projects and case studies from the DI Labs FDM hub
- The challenges and learning lessons coming out of this beta environment
READ THE FULL STORY: https://dilabs.cc/di-labs-is-first-in-the-world-to-free-the-fortus-as-a-stratasys-global-launch-partner-for-the-openam-beta-on-the-fortus-450mc/
Episode Topics
0:28 Our intention with this podcast
1:25 Welcome, Tom Leach
2:52 Why tune into this podcast
3:28 Something we've never done before
5:37 From a closed system to OpenAM
6:51 Manufacturing and material suppliers
7:39 Partnering with chemical suppliers for unique applications
9:18 From prototyping to manufacturing
9:52 Technical challenges of the OpenAM
11:41 Why Stratasys chose DI Labs
14:22 Focus on highly engineered materials
15:20 Three Stratasys material paths
19:22 Success with OpenAM
20:11 Fine-tuning parameters adds capability
20:57 Past bottlenecks with FDM
21:56 OpenAm changed the game
23:02 Accuracy, repeatability, reliability study
26:52 Zero machine downtime with Fortus
27:38 Thank you
LEARN MORE ABOUT DI LABS: https://dilabs.cc
Welcome to the "Free the Fortus" Podcast (now called the Solutionology Podcast), fueled by the Stratasys #OpenAM Validated Materials Beta underway at DI Labs. We're a Stratasys global launch partner for this groundbreaking program that will free the Fortus 450MC of its closed system limitations and unlock the potential of the industry's most powerful FDM platform. The Stratasys #OpenAM Beta will give DI Labs unprecedented freedom to modify the process settings and other adjustments necessary to successfully run new, highly engineered materials such as PAEK, PEKK and Glass Filled Nylon 6/66. It’s never been done and we’re confident that the outcome will change what’s possible for additive manufacturing in service of high-performance industries like medical device, aerospace, electronics, industrial and automotive industries.
Watch the full episode on YouTube!
https://youtu.be/XXjLdnaGb24
Our second guest is Nate Litmer, KIMYA Business Development Manager North America. He explains the role engineered materials are playing in the expansion and advancement of additive solutions for high-end applications.
READ THE FULL STORY: https://dilabs.cc/di-labs-is-first-in…
Episode Topics
00:29 Welcome Back
00:51 Update on Week One Beta Program
02:48 Running the OpenAM interface
03:19 Our guest today
04:46 We need more problem solvers
05:31 Introducing Nate Litmer
6:54 About KIMYA - Materials, Lab & Factory
7:47 Utilizing additive in industrial manufacturing
8:42 Increasing efficiencies & change the mindset
9:26 Materials vs Factory customers
10:57 The process for running new materials
11:55 Pairing a reliable system with high quality products
12:19 Variability of open systems
13:16 Opportunities for scaling production
14:01 Supply chain issues solved with additive
15:45 Paradigm shift from traditional to additive
16:48 Application examples with engineered materials
18:30 Challenges with open source equipment
19:23 Technical team required
20:41 Getting the first successful part out
21:37 Enabling challenging applications
22:08 Missed opportunities in our industry
23:16 Working with a new generation
24:55 Being less reliant on the laggard legacy supply chain
25:49 Future for KIMYA with materials
27:40 Engineered materials and Fortus open opportunities
28:26 More materials for the validated materials beta
29:34 Thanks for your time
LEARN MORE ABOUT DI LABS: https://dilabs.cc