Some time has passed, but my first AMUG definitely lived up to the hype.

It was great catching up with familiar faces and meeting new ones, but the real value was the learning. One of my biggest takeaways came from the keynote by Steve Fournier of General Atomics Aeronautical Systems, Inc. and Scott Sawyer of Divergent Technologies.

Not because of the technology itself - but because of how they approached adoption.

When Additive Becomes a Pitch

• Most additive manufacturing conversations start the same way:
• Features
• Benefits
• Design freedom
• Part consolidation
• Speed

Every company and every machine have something that stands out. Don’t get me wrong, that’s valuable. But these are also the easiest things to talk about. They’re not the conversations that change a business.

A Different Starting Point

What stood out here was simple: They didn’t start there. Instead, they started by challenging the idea itself. Divergent had already proven their additive-driven, software-defined manufacturing model in automotive. Their platform integrates:

• Design software
• Additive production
• Automated assembly

All within a fully digital manufacturing system.

Expanding Into Aerospace - Without Assumptions

The next step was expanding into aerospace and defense through their partnership with GA-ASI, specifically around unmanned aircraft systems.

On paper, it made perfect sense:

• Lightweight structures
• Complex geometries
• Performance-driven design

All strong fits for additive.
But they didn’t assume it would translate.

They Pressure Tested It

Instead of building a case for why additive should work…They focused on where it might break.

They asked:

• What carries over from automotive?
• What doesn’t translate?
• What still needs development?
• Where does the process fall short under new demands?

Because aerospace brings:

• Different requirements
• Different risk tolerance
• Different qualification standards
• Different expectations for performance and reliability

The Mindset Shift

• From selling the technology → to validating the application
• From proving upside → to exposing risk
• From excitement → to discipline

This is where additive stops being interesting…and starts becoming business-critical.

Where Projects Actually Succeed (or Fail)

This approach forces a deeper level of thinking:

• Beyond the machine → into the workflow
• Beyond a single part → into repeatability
• Beyond a pilot → into production

It does three things:

1. Challenges assumptions early
2. Aligns teams faster
3. Prevents investment in solutions that won’t scale

Because this is where most additive initiatives either gain traction or quietly stall out.

The Questions That Actually Matter

It’s easy to find parts that look like a good fit:

• Consolidated designs
• Reduced assembly
• Lightweighting

But that’s just the starting point.
The real questions come after:

• Can the material meet long-term requirements?
• Can the process support production volumes?
• Does post-processing become a bottleneck?
• Will teams actually adopt and design for it properly?
• Can the business support it beyond a pilot phase?

If those answers are unclear…The project is already at risk.

Pressure Testing Isn’t Negative, It’s Necessary

This level of scrutiny isn’t pessimistic. It’s strategic.

• If the idea fails early, you save time, money, and resources
• If it survives, you move forward with something that can scale

How We Approach It at M5D

At M5D, this is how we approach additive:

• ·Not just where it fits
• But where it holds up under real conditions
• Not just what it can do
• But what it can’t

Because the goal isn’t to force additive into the process.

The Real Goal

The goal is to find where it actually works and build from there.

That’s what drives real adoption.
Not hype. Not features.

 But applications that survive the test. 

Evaluate Where Additive Actually Works

If you're exploring additive manufacturing, the biggest risk isn’t choosing the wrong machine—
it’s moving forward without validating the application.

At M5D, we help teams pressure test additive before they invest.
Schedule an Additive Assessment here, Zach Carr

Zach Carr
zcarr@m5d.com
(312) 982.426

At M5D, we know 3D printing is about delivering results that are strong, fast, consistent, and cost-effective.  That's why we've partnered with Formlabs, whose latest ecosystem—from materials to machines—is built to solve the most common bottlenecks in modern additive workflows.

Here's how: 

Material Library: Expand Your Possibilities

Current problems:

• Parts fail to meet performance expectations due to limited material capabilities
• You're forced to turn away projects you don't have the right materials
• Outsourcing specialty parts adds cost, delays, and risks
  
  

Solution:
Formlabs offers one of the most diverse resin and powder portfolios on the market—from engineering-grade nylons to biocompatible, flexible, and heat-resistant resins.  Print prototypes, tools, and end-use parts all in-house, and take on more projects without hesitation.  Even supports Open Material Licensing on Form 4 and Form 4L.

The largest selection of resin and powder-based materials in the industry are at your fingertips.
The booklet for all their materials is down below.

Formlabs Material Library.pdf

Form 4 / 4L: Speed, Reliability, and Flexibility

Current problems:

• Long print times delay innovation and delivery.
• High outsourcing and material costs eat into your margins.
• Inconsistent quality and part failures impact trust.
• Limited build volumes restrict part size and throughput.

Solution:
The Form 4 and Form 4L combine blazing-fast print speeds, automated resin management, and precision optics to deliver high-quality parts in less time—with build volumes to match your ambition.  Reliable, scalable, and ready to grow with you.

Check out the following pdfs on our 3D resource page:  Form 4L vs Form 3L & Form 4

Fuse 1+ 30W: Industrial-Grade SLS, Reimagined

Current problems:

• Weak or fragile prototypes that don't survive real-world use.
• Inconsistent results make it hard to scale or standardize.
• Production grade applications cannot be pursued because of expensive equipment.
• Wasted powder and limited in-house capabilities force outsourcing.

Solution:
The Fuse 1+ brings production-ready SLS printing to your workspace—with powerful lasers, recyclable materials, and a compact footprint.  Durable parts, repeatable results, and an ecosystem (Fuse Sift & PostFuse) that's built for true in-house manufacturing.  The most ground-breaking part of the system is that the investment starts as low as $20,000.

Check out the following pdfs on our 3D resource page: Fuse 1 Ecosystem pdf

Automation: Less Hassle, More Output

Current Problems:

• Time-consuming post-processing slows your team down.
• Manual resin handling and material changes lead to delays.
• Powder handling is messy and inefficient.
• Tracking consumables and usage becomes guesswork.

Solution:
With automated resin dispensing, powder recovery, material detection, and workflow integration, Formlabs systems are designed to reduce manual steps and maximize output. You focus on creating—the machines handle the rest.

View the following pdfs on our 3D resource page: Fuse 1 Ecosystem, Form 4 & 4L Ecosystem, & Resin Wash  

Ready to Level Up?

If these problems sound familiar, you're not alone—and you're not stuck.  With this partnership with Formlabs, a comprehensive digital manufacturing solution and technology-focused adoption team is available to tackle these exact problems.

Read more about Formlabs partnership or talk to me, Zach Carr, about how to bring this technology in-house.

Zach Carr
zcarr@m5d.com
(312) 982.4268