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

HP has just introduced the HP IF 3D 600HT, a high temperature industrial filament printer developed from the proven 3DGence Industry F421 platform—a system Cimquest has supported for years.

Many manufacturers tell us they’re struggling with applications that require more from their materials: greater heat resistance, improved chemical durability, or a lightweight alternative to metal. The 600HT addresses these challenges by enabling printing with ULTEM, PEEK, PAEK, and carbon fiber reinforced polymers—materials that aren’t achievable on powder bed systems like MJF or SLS.

Organizations working in aerospace, energy, medical, rail, and automotive also frequently ask for better consistency when working with high performance polymers. The system’s integrated Materials Management System (MMS) helps resolve these issues by drying, conditioning, and even annealing materials like PEEK to improve strength and ensure repeatable output.

Because this platform is built on an architecture our team already knows well, M5D customers can move into high performance filament printing without the uncertainty that typically comes with adopting a new technology. The 600HT simply extends HP’s ecosystem into applications where customers have been asking for more capability and more material flexibility.

A few questions to consider:

• Are heat, chemicals, or load causing failures with your current printed parts?
• Would access to ULTEM, PEEK, or carbon fiber–reinforced polymers change what you can take on?
• Is variability in filament printing limiting your ability to produce repeatable, production‑grade parts?
• How important is an open, industrial workflow for your next round of applications?

If any of these sound familiar, connect with us and we can compare notes and see whether the 600HT fits your workflow.

Dave Macfie
3D Printer Sales
Direct: 908-655-5484
Email: dmacfie@m5d.com

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

That question came from Shane Jetton during a conversation—and it stuck with me.  In an industry full of big promises and even bigger price tags, it's a fair question to ask.  At M5D (formerly MasterGraphics), we've been deeply involved in metal additive manufacturing for years.  And like many others in this space, we've made some expensive mistakes—investing in systems that didn't live up to the hype.  So when One Click Metal approached us about becoming a reseller,  our initial reaction was skepticism.  Affordable DMLS printing with industrial-grade output? It sounded like another lofty promise. But after doing the research—speaking with other resellers, end users, and evaluating their product line—we decided to move forward.

One Year In:  One of Our Best Decisions in Additive Manufacturing

Now, nearly a year later, we've installed over 10 One Click Metal systems across a range of customers—from small shops to enterprises.  And we're confident in saying this was one of the two best AM decisions we've made in the last decade (the other being HP in 2017).

Here's why:

1. Simplified & Safer Powder Handling

One Click's cartridge-based powder management system drastically reduces direct interaction with metal powders, improving both safety and cleanliness on the shop floor.  The integrated MPURE station automates depowdering and sieving, making unused powder easy to recycle and reuse—a crucial feature for cost control and sustainability.

2.  Industrial-Grade Hardware in an Accessible Package

Despite its compact size and lower price point, the MPRINT+ system is packed with serious performance:

• 200W Fiber Laser
• Galvo Scanner with scan speeds up to 3000 mm/s
• Focus diameter of 45 microns
• Build Volume of 150 x 150 x 150 mm

This makes the system ideal for both prototyping and low-volume production.

3. Cost-Effective and Scalable

Lead with price?! I always believe that any solution needs to start wit the "pain" first to see if there is even a solution.  The clear ground breaking part of the system is a total system price around $200,000, One Click offers a far more accessible entry point into metal AM compared to traditional DMLS systems, which often exceed $800k.

Want to break it down even further?  You're looking at about $5K/month, including equipment and maintenance.   That's a very manageable entry point—and a strong starting ROI for SMBs, service bureaus, or educational institutions.  

4. Modular Design for Future-Proofing

The BOLDSERIES platform includes:

• MPRINT+ Printer
  • Ask me about the lab print module - an innovative way to run different materials!
    
• MPURE Processing Station
• MONE 3D Print Software

This modular ecosystem makes upgrades and servicing far more manageable, ensuring that customers can scale their system as their needs evolve.

5. Remote Monitoring & Control

Through the MONE software, users can remotely control and monitor print jobs from anywhere—ideal for busy teams or distributed production environments.

Real-World Performance: Side-by-Side with the Big Guys

We've installed One Click systems alongside legacy DMLS systems that cost nearly four times as much—and the results are comparable.  That's not just a selling point, that's proof.  While no system is perfect—and One Click continues to improve, especially in their OS—we're confident in the solutions.  So confident, in fact, that we've personally guaranteed success to our customers.  

Final Thoughts

If you've been skeptical of metal AM systems, you're not alone.  If you've been burned in the past, we've been there too.  But the One Click Metal system is the real deal:  safe, scalable, and affordable—without sacrificing performance.  So, can you trust a $200K DMLS system?

Yes—you can!

And we believe it's changing the landscape of metal 3D printing.

If you'd like to see it in action, learn more, or talk to other customers, we'd be happy to connect you with the right people—even if you're outside our region.

M5D One Click Metal webpage

Thanks for reading!

Kevin Carr
President | M5D
kcarr@m5d.com

M5D will be hosting a seminar on Additive Manufacturing during the Annual SPE Thermoforming Conference.  This conference is dedicated to educating attendees on the development and application of thermoformed products, covering both thick and thin gauge materials.

The Additive Manufacturing track will focus on how digital manufacturing technologies are being integrated into the thermoforming industry.  Attendees will learn how these innovations can accelerate time to market, reduce costs, expand manufacturing capabilities, and support creating more cohesive production systems.  

The seminar will feature the following presentations:

1. Large-Format Printing with the Titan Pellet Extruder by 3D Systems
   This session will explore how large-format 3D printing is being used to produce thermoforming molds across various industries.  A featured case study will showcase a motorcycle fairing made from thick-gauge material, with intricate backside details created using 3D Systems' PSLA process.  The components were assembled using adhesive bonding, highlighting benefits such as faster lead times and cost savings.
2. Polypropylene (PP) Printing and Assembly with Forecast 3D
   This presentation will demonstrate how Forecast 3D leverages PP-based additive manufacturing to create detailed components for assemblies.  These parts are designed to integrate with PP-based materials like TPO and enable traditional plastic welding methods.  The process supports efficient digital manufacturing while maintaining compatibility with existing thermoplastic joining techniques.
3. Tooling with Binder Jet Sand Printing by Catalysis 3D
   Catalysis 3D will showcase how binder jetting with sand can produce high-performance thermoforming tools.  This approach results in durable molds with improved thermal characteristics and rapid development timelines, offering a cost-effective alternative to conventional tooling methods.

To conclude the seminar, I will present on Adding Value to Products Through Digital Manufacturing.  My talk will examine how emerging technologies evolve into essential enablers, focusing on the strategic benefits that digital manufacturing can bring to a product portfolio.

Click here to register for the 2025 SPE Thermoforming Conference in Atlanta, Georgia May 19-21, 2025 

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? 

Please 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:

1. How embracing Additive Manufacturing can reshape your product development approach, fostering agility and sparking creative ingenuity.
2. Why having a structured process for product development through Additive Manufacturing is not just advantageous, but essential.
3. 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.

Watch Video

What you'll learn...

Uncover the transformative power of 3D printing in our webinar.  Learn how it drives revenue growth, revolutionizes product development, and enhances the customer experience.  Unlock the immense potential of 3D printing for growth and innovation in your business.

You'll hear from:

• David Tucker, Business Development Consultant, New Wave Manufacturing
• Carl Douglass, CEO, Di Labs
• Kevin Carr, President, MasterGraphics
• David Rosendahl, President, MindFire Inc., Moderator

In this session, our panelists break it all down and discuss:

1. What the terminology "solutionologist" means.
2. How to leverage additive manufacturing through a product development process beyond simple prototyping.
3. Where they see the largest opportunity for additive in developing new product portfolios.
4. David explains his customized innovation workshops that empower customers to maximize the potential of additive manufacturing.
5. The term, "creating a digital product portfolio", really means.

In the webinar, we addressed attendee questions on the potential and impact of additive manufacturing in manufacturing and businesses, while also exploring solutions to address customer challenges.

Watch this webinar recording now to start off on the right foot and get answers to questions you may have or may have not even thought of!

Watch Video

What you’ll learn…  

In the third panel discussion of our three-part series, you’ll get answers to key questions from three additive manufacturing leaders who don’t shy away from the truth and have critical insights to share.  

You’ll hear from:  

• Kevin Carr, President, MasterGraphics
• David Tucker, Business Development Consultant, New Wave Manufacturing
• Michael Rosplock, Manager of Digital Manufacturing, Enerpac
• David Rosendahl, President, MindFire Inc., Moderator  

In this session, our panelists break it all down and discuss what is needed to leverage best-in-class 3D Print manufacturing processes with these five considerations:

1] Why it is imperative to write an effective proposal to convince the required executives and the technical team that new 3D print technology is a worthy investment. The need to justify the expenditure. 

2] The importance of designating a project lead and the value they bring to achieving effective implementation. 

3] The project leader's ability to focus on part development that leverages the additive manufacturing cell effectively. 

4] The need for understanding the proper AM cell setup and the expected production processes. 

5] The key to success also includes focusing on the factory blueprint layout that outlays the physical workflow from print to finish.

Watch this webinar recording now to start off on the right foot and get answers to questions you may have, or may have not even thought of!

What you'll learn...

In the second panel discussion of our three-part series, you'll get answers to key questions from three additive manufacturing leaders who don't shy away from the truth and have critical insights to share.  

You'll hear from:

• Kevin Carr, President, MasterGraphics
• Dennis Richards, CO, Certified Orthotist, 3D Stability
• Vince Anewenter, Director of Rapid Prototyping Consortium, Milwaukee School of Engineering
• David Rosendahl, President, MindFire Inc., Moderator

In this session, our panelists break it all down and discuss:

1) Why now IS the right time to invest in additive manufacturing and restore your supply chain (in the face of a looming recession).

2) Surefire ways to find and land profitable opportunities, assess cost-effectiveness and prove the value of AM.

3) The best ways to avoid common startup challenges and set yourself up for success.

4) How learning to design for AM will enable you to maximize your capabilities and profit.

5) Determine when/how to bring AM in-house and what to consider once you do!

Does the looming recession have you worried? Confused about the path forward for your business? Or terrified to make a costly misstep?

If so, you're not alone.  Many companies are turning to additive manufacturing as a solution—and you can, too!  But in order to optimize your success with this technology, you'll need to know where to start and what steps to take to set yourself up for success.

Watch this webinar recording now to start off on the right foot and get answers to questions you may have, or may have not even thought of!