#240 General Atomics' Steve Fournier on 3D printing thousands of aircraft parts

On this episode of the Additive Insight podcast, we're joined by Alex Hickson and Matt Bailey of the Aerospace Technology Institute. Hickson and Bailey are both part of the ATI’s Structures, Manufacturing & Materials team, with Hickson serving as Head of Technology and Bailey as a Lead Technologist. Through their roles, Hickson and Bailey have contributed to the development of additive manufacturing and wider technology strategies that seek to support the adoption and application of advanced design and manufacturing techniques. As they join the Additive Insight podcast, the pair provide their perspective on the challenges and opportunities around AM implementation in civil aerospace, while sharing the progress made since the release of its AM strategy in 2024. We also discuss what will be needed to meet net-zero targets by 2050 and how those in industry can support the organisation moving forward.

On this episode of the Additive Insight podcast, Jonathan Rowley joins us to talk about Additive Companion, a new platform designed to help navigate the complex world and parlance of additive manufacturing (AM). Rowley, a qualified architect and Associate Lecturer in MA Design for Industry 5.0 at Central Saint Martins, UAL, shares his 'Raider of the Lost Ark' lightbulb moment with 3D printing, why bringing 'objects' to the forefront of the AM conversation is crucial to successful adoption, and how eight years running a London-based 3D printing bureau equipped him with the tools to help cut through the noise and launch a resource built on purposeful case studies.

On this episode of the Additive Insight podcast, Joe Allison, a 3D printing veteran and the latest inductee to the TCT Hall of Fame, joins us for a conversation spanning over three decades in additive manufacturing. As co-founder of one of the largest suppliers of 3D printed parts back in 1991, Solid Concepts, Allison's contributions to the AM space include the development of industry‑first software tools, such as automated support‑generation software for stereolithography and a universal CAD viewer, right the way through to securing the first third party certified SLS parts for Boeing to taking on 'the funnest job in the industry'. During this conversation, Allison takes us back to 1988 and starting out in the 3D printing Wild West, the brutal process of getting those first Boeing parts certified, and the 'moments of brilliance' that have captured his attention throughout his AM career.

On this episode of the Additive Insight podcast, we're joined by SecurePrint3D founder Ranjith Gopalakrishnan. SecurePrint3D was founded last year and has been granted a patent for a hardware-enforced print authorisation technology that has been designed to facilitate the implementation of distributed additive manufacturing. Distributed manufacturing has long been considered a concept that AM can enable, but several barriers remain, including: the authorisation gap. Though still at an early stage, Gopalakrishnan joins the Additive Insight podcast to explain the capabilities of the hardware-enforced print authorisation technology, where it fits in the existing AM landscape, and how far along the company is on its commercialization journey. He also provides insight into initial research discovery and outlines what success will look like for the company.

On this episode of the Additive Insight podcast, we're joined by XJet CEO Guy Zimmerman. XJet came to market with its NanoParticle Jetting technology nearly a decade ago, and is establishing itself as a supplier of ceramic and metal AM solutions in a range of sectors. Recently, the company has expanded its product portfolio with the Carmel 5000X and Carmel Pro printers, while also expanding into the printing of precious metals. As Zimmerman joins the podcast, he explains what has driven the evolution of its product portfolio, the key considerations that need to be made when building an AM business case, and why his optimism for the AM space is growing. He also outlines his vision for XJet, and tells us what we can expect next from the company.

On this episode of the Additive Insight podcast, we're joined by Amnovis CEO Ruben Wauthle. Amnovis is a manufacturing production service that supplies parts to the medical and industrial sectors. Having first established itself in the medical sector, Amnovis last year produced and delivered its 100,000th implant, with the company increasingly looking to expand its offering to industrial markets. Joining the Additive Insight podcast, Ruben explains the growth of the company over the last five years, shares how it has scaled up its manufacturing operations to produce 60,000 implants a year, and provides details on an ongoing R&D effort to print with multiple materials via metal powder bed fusion technology. He also opens up on his vision for the company moving forward.

On this episode of the Additive Insight podcast, we're joined by Steve Fournier, Senior Manager, Additive Manufacturing at General Atomics Aeronautical Systems Inc. (GA-ASI). Fournier speaks to TCT ahead of a joint keynote presentation at this year's Additive Manufacturing Users Group Conference, which, together with Divergent Aerospace and Defense's Scott Sawyer, will share how General Atomics and Divergent struck up a valuable partnership at this very event. We dive into this story of AM knowledge exchange, plus how Fournier helped to establish GA-ASI's Center of Excellence for its Additive Design and Manufacturing, and General Atomics thousands of flying 3D printed parts. Fournier also teases that AMUG attendees will have a chance to see some hardware up close.

On this episode of the Additive Insight podcast, we're joined by NexusAM CTO Sebastian Larsen. NexusAM is in the process of developing an AI-powered in-situ monitoring capability for metal additive manufacturing. Larsen, a member of the co-founding team, joins the podcast to discuss the engineering challenges Nexus AM is working to solve and the progress the company has made so far. He shares details on the proprietary AI stack that underpins much of the platform’s capability, how the company is making additive manufacturing more economical, and how it is leveraging industry feedback to further develop its flagship product. Larsen also reveals when the in-situ monitoring platform will be commercialised and his vision for the company.

On this episode of the Additive Insight podcast, we're joined by Firestorm Labs CTO Ian Muceus. Firestorm Labs is a manufacturer of mission-adaptable unmanned aerial systems and is a big proponent of additive manufacturing technology. The company has a portfolio of additive-enabled drone products, including its flagship Tempest UAS, and has also developed the semi-automated xCell manufacturing platform which utilises Multi Jet Fusion technology within 20-foot containers. As he joins the Additive Insight podcast, Muceus provides detail on the capabilities of both Firestorm’s drones and xCell platform, while sharing his perspective on the impact AM is having within the drone space. Muceus also explains how the company will utilise the funds raised in its recent Series A round and tells us how Firestorm’s application of AM may evolve moving forward.

On this episode of the Additive Insight podcast, we are joined by Foundation Alloy CEO Jake Guglin. Foundation Alloy is taking solid-state metallurgy developed at MIT and UC Irvine and using it to produce next-generation alloys capable of performing in the most extreme environments. With its proprietary MetalsFIRST technology, the company officially launched a series of molybdenum alloys in November of last year. These alloys are said to exhibit significant increases in strength compared to competitor products, with Foundation Alloy confident they can meet the needs of manufacturers in aerospace, defence and energy. Joining the Additive Insight podcast, Guglin explains how the MetalsFIRST technology works, shares how much progress has been made with customers so far, and outlines the application opportunities for molybdenum alloys moving forward.