Explore every episode of the podcast Solutionology Podcast
Dive into the complete episode list for Solutionology Podcast. Each episode is cataloged with detailed descriptions, making it easy to find and explore specific topics. Keep track of all episodes from your favorite podcast and never miss a moment of insightful content.
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Title
Pub. Date
Duration
Ep #30 | PART TWO: The Paradigm Shift of Mass Customization with Stephanie Hendrixson, Editor-in-Chief of AMM
05 juin 2025
00:13:51
In Part Two of this Solutionology Story, Stephanie Hendrixson, Editor-in-Chief at Additive Manufacturing Media, dives deeper into the paradigm shift of mass customization in manufacturing. She recently reported on the topic directly from the DI Labs facility in Minnesota.
Stephanie talks with Brian and Carl Douglass about how AM is redefining production by enabling uniquely tailored products on demand, enhancing consumer satisfaction, and optimizing production processes. Hear about real-world applications like personalized eyewear and footwear, the role of AI in design and manufacturing, and Stephanie’s vision for the future of mass customization. This episode offers practical insights and explores the significant shift from mass production to individual customization.
Ep #30 | PART ONE: Exploring Stories & Innovation in Additive Manufacturing w/Stephanie Hendrixson, AM Media
03 juin 2025
00:13:58
Stephanie Hendrixson, Editor-in-Chief at Additive Manufacturing Media, joined Brian and Carl Douglass on Solutionology Stories episode #30 to share some fascinating stories and groundbreaking innovations in additive manufacturing (AM). In fact, the episode was so good that we split it into two parts!
In Part One, Stephanie shares the unexpected path she traveled from English literature to additive manufacturing and what inspired her to become a teacher and storyteller about highly technical topics in manufacturing. She has been recognized among Temboo's 20 Women Influencing Manufacturing and plays a critical role as an educator and advocate shaping the future of additive! She's incredibly enthusiastic about the future of additive manufacturing and says, "If you've held back (from exploring additive) because you're waiting for the right time, the right time is anytime! Just jump right in."
She provides insights into AM’s rapid growth and shares experiences hosting "The Cool Parts Show" and "AM Radio Podcast."
Ep #29 | Distributed Manufacturing & the Tipping Point of Additive
27 mai 2025
00:12:40
In this follow-up to Part One of our conversation with Bud Runquist, VP of Sales and Marketing at Stratasys Direct, we go beyond the incredible disaster response story of additive manufacturing told in Episode #28. (https://youtu.be/t0GsB9hil3w)
As two leaders deeply embedded in the additive manufacturing space, DI Labs and Stratasys Direct share a mutual commitment to raising the bar for quality, reliability, and scalable production. Together, they explore how distributed networks of trusted partners can provide rapid, resilient responses to supply chain disruptions—something both companies have experienced firsthand.
Bud outlines how additive is moving beyond prototyping into just-in-time, localized production, offering dramatic cost and logistical advantages. Carl and Brian reflect on their own challenges and successes in building confidence among clients and suppliers, reinforcing that standardization, validation, and collaboration are critical for additive to reach its full potential.
The discussion ends with a powerful focus on medical applications, a space where both Stratasys Direct and DI Labs see immense potential to improve lives. With passion, technical insight, and shared optimism, this episode offers a compelling look at how distributed manufacturing is not only possible—it’s already happening.
00:00 – Intro: Why Distributed Manufacturing Matters 01:00 – Why Distributed Manufacturing Is Gaining Ground 05:40 – From Shelf Space to Digital Warehouses 07:17 – Where Are We in the Additive Adoption Curve? 09:19 – The Culture of Collaboration 10:16 – Medical Applications: Additive’s Next Big Opportunity 11:35 – A Call to Innovate and Push Boundaries 12:27 – Wrap-Up and Appreciation
Watch PART ONE of this Solutionology Stories conversation: https://youtu.be/t0GsB9hil3w Follow our Solutionology Stories Playlist: https://youtube.com/playlist?list=PLMo39wYkklXud2wHcfBRLQ2_cMjl0B3hQ&si=YtWMfJpMhUFmhUfT More about DI Labs: https://dilabs.cc/ More about Stratasys Direct: https://www.stratasys.com/en/stratasysdirect/
Episode #28 | How Additive Manufacturing Stepped Up When Disaster Struck
06 mars 2025
00:29:50
The Story of a Distributed Manufacturing Response Led by Stratasys Direct
In October 2024, a major hurricane struck the U.S., leaving destruction in its wake—including the disruption of a critical injection molding supply chain for a top automotive manufacturer. With production at a standstill and losses mounting by the hour, the company turned to Stratasys Direct, one of the world’s largest additive manufacturing service providers, for a solution. Justin "Bud" Runquist, VP of Sales and Marketing at Stratasys Direct, led the charge in mobilizing an emergency manufacturing response. They quickly recognized that meeting the demand—500 parts per day, with the first shipment needed within seven days—required a network approach and reached out to trusted partners, including DI Labs, to expand capacity.
The response from the additive manufacturing community was overwhelmingly positive. Manufacturers across the industry stepped in, demonstrating the power of distributed manufacturing: a collaborative, decentralized approach that allows for rapid scaling.
In this episode of Solutionology Stories, hosts Carl and Brian Douglass sit down with Bud to talk about the challenges, innovations, and impact of this inspiring story and how it can be a blueprint for additive manufacturing's role in times of crisis and beyond.
00:00 Welcome Bud 02:31 Line Down! 11:00 Quality Standards for Distributed Manufacturing 15:21 Pushing Use Cases for Volume Production 25:34 A Tipping Point for Additive Manufacturing
Episode #27 | A CEO’s Formula for Driving Innovation Through Commitment, Culture & Relationships
06 mars 2025
00:25:25
Welcome to the latest edition of our Solutionology Stories newsletter and podcast featuring insights from our client, Jamie Duininck the CEO of Prinsco, Inc. He's a third-generation owner and leader of a family business that provides water management solutions to the agricultural, stormwater, residential, and onsite markets. Jamie is a creative, out-of-the-box thinker who is well respected across his company and industry for his leadership, candor, and ability to build relationships that have positively impacted his company's opportunities for growth and success.
In this episode, Jamie shares the formula he's developed and used over his 28-year career to successfully drive innovation and embrace change. His perspective offers valuable lessons for anyone seeking to make a lasting impact in their field.
00:00 Welcome 01:25 A Journey From Sales to CEO 03:06 Driving Innovation 11:10 Pro4 Story 20:34 Rewarding Relationships 21:38 Lessons on Leadership
Episode #26 | From Concept to Launch: Developing a Disruptive Product Portfolio Using a Digital Mindset
27 janv. 2025
00:38:34
Join us behind the scenes of DI Labs' largest product development and launch program to date, powered by a digital-first approach. Spanning eight years, this transformative journey began in 2015 with a rough business plan. It culminated in 2024 with the launch of a groundbreaking four-model product portfolio for Prinsco, a leader in water management solutions. Our guests on this episode of Solutionology Stories are Jason Ahrenholz, Prinsco's Director of Engineering, and Judd Effinger, Prinsco's Onsite Sales Manager.
Prinsco set out to disrupt a monopolized market by introducing a high-performance product alternative in the onsite septic industry. Achieving this vision required an unprecedented commitment to resource allocation, leadership alignment, and long-term success—all underpinned by a digital mindset.
As Prinsco's development partner, DI Labs utilized cutting-edge digital manufacturing techniques, including additive manufacturing, to innovate, prototype, and create a full-scale model for prelaunch marketing. Tune in to discover how this digital approach enabled breakthrough solutions and redefined product development success.
00:00 Intro 03:24 Market Opportunity 7:47 Injection Molding to Thermoforming 15:41 Back to Injection Molding 24:06 Market Launch 31:01 Project Takeaways
Episode #25 | Approaching Quality & ISO 9001 with a Digital Mindset
26 avr. 2024
00:22:16
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
Episode #24 | Using a Digital Mindset in Product Development & Manufacturing
25 mars 2024
00:22:30
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.
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.
Episode #23 | Maximizing Value Using a Digital Mindset
19 déc. 2023
00:13:41
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
Episode #22 | Do You Have A Blueprint for Additive Manufacturing Success?
13 nov. 2023
01:26:06
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.
Episode #21 | When to Consider Additive Manufacturing for Production
11 oct. 2023
00:14:46
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
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
Episode #20 | Driving Design Complexity Using Additive Manufacturing for Production
15 sept. 2023
00:14:37
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.
Episode #19 | Insights from a 30-Year Career in Product Design w/ Mike Van Staagen
29 août 2023
00:37:29
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
Episode #18 | The Impact of Rapid Modeling at Full Scale: Cirrus Fuselage
21 août 2023
00:14:59
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
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
Episode #16 | Leveraging 3D Printing to Drive Thermoforming Innovation
16 juin 2023
00:36:12
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.
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
Episode #15 | PAEK: The Superhero of Ultra-High-Performance Materials
08 mai 2023
00:57:00
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
Pain Point #5: Short Term Thinking vs Long Term Solutions
26 avr. 2023
00:13:19
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.
Pain Point #4: Making Promises vs Delivering on Promises
19 avr. 2023
00:10:25
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?
Pain Point #3: Promoting Quality vs Ensuring Quality
10 avr. 2023
00:09:54
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.
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.
Pain Point #1: Buying a Printer vs Building a Digital Workflow
24 mars 2023
00:10:18
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.
Episode #12 | The Two-Week Effect: A Friendship that Shaped Our Culture
17 févr. 2023
00:21:58
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
Episode #11 | Supporting Transformational Innovation in Medical Device
26 janv. 2023
00:32:43
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.
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
Episode #10 | Discovering the Power of Additive: Phytec's Journey
12 janv. 2023
00:38:50
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.
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
Episode #9 | The Journey Behind Our Mass Customization Use Case
12 janv. 2023
00:42:14
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.
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
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
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.
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
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.
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
Episode #5 | Advancements with White Parts
11 janv. 2023
00:14:03
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.
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
Episode #4 | The Art of Onboarding Materials & Technologies
11 janv. 2023
00:24:20
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!
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
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.
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
Episode #2 | Opportunities with Engineered Materials
11 janv. 2023
00:30:21
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.
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.
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
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.
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
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