Ford House, Visitor Center in Grosse Pointe Shores, Michigan

I recently attended Innovation Unleashed: AI, Additive Manufacturing, and Cybersecurity Shaping Industry 4.0, a Michigan event hosted by Integr8 at the Ford House Visitor Center. I joined local Grosse Point expert, David Tucker, to bike to the venue! The wind was against us the whole way, but the views of beautiful homes along Lake Short Rd made for a great journey.

Biking route from Grosse Point to Ford House, Grosse Pointe Shores

It was great to see the local Detroit manufacturing community come together for real conversations about where things stand today, where progress is stalling, and how real forward movement might happen—by better connecting technology, talent, and execution.  Here are a few key themes that stood out. Sprint Mixer including Panel Experts from the Sponsors above

1.  Workforce: What's Missing?

The panel kicked off with workforce development. Manufacturing companies have open roles—how do we fill them? Is it a pipeline issue, a training gap, or something else entirely? 

From my perspective, a major challenge is the lack of manufacturing career exposure in high school and college—whether that's awareness of available roles, career paths, or advancement opportunities.  Thinking back to my 18-year-old self, I only felt confident pursuing education tracks that have been discussed by parents or family friends.

One suggestion that stood out was "pair programming" for manufacturing—a technique borrowed from software development where two collaborators with different skill levels or specialties work side-by-side.  The approach helps both people improve while also delivering better results.  The result isn't just stacking—it's skill multiplication.  So, how can this model be practically implemented in manufacturing and engineering environments?

2.  AI: Making Use of Internal Data

Most manufacturers have an invaluable resource of data at their fingertips.  The real challenge lies in structuring it, harnessing it, and putting it to work.  A key takeaway from the discussion: operational data might be the most valuable asset a manufacturer owns—but it only delivers value when mined, analyzed, and acted on, securely.

Quick aside: I'm also attending the Automate Show in Detroit this week.  On the first day, I joined a talk with Nvidia and Vention, focused on their latest AI + vision system integrations.  As someone new to concepts like RGB-D vs. lidar and the broader world of vision systems (which even connects to autonomous vehicles), it was a fascinating session.

3.  Additive Manufacturing: Still on the Launchpad

At the last two trade shows, several attendees shared the view that additive manufacturing can't yet support production-scale manufacturing.  While that may be true in some cases, there are still plenty of opportunities worth exploring.  So why does the shift from prototyping to production still feel like a crawl?

Key barriers to adoption include inconsistent print quality across batches, a lack of widely accepted qualification frameworks, and limited scalability in current workflows.

One recurring idea from the panel came from Brenda Jones, CEO of Ulendo: the tradeoff in 3D hardware between going broad versus deep.  Flexible, general-purpose machines offer adaptability—but may sacrifice speed or precision.  In contrast, niche machines are highly optimized for a single job but tend to come with higher costs and less flexibility.

Should hardware manufacturers focus more deeply on specific applications and dial in their processes?  Or is there still a viable place for jack-of-all-trades systems in production environments?

One example is SLA-based systems like Asiga print pods used in dental offices—a great use case of purpose-built technology.  But can this same strategy be applied to other industries?

My instinct says there are only a few applications or industries where the opportunity is big enough to justify deep R&D into a specialized printer.  But here's the counterpoint: is today's general-purpose technology actually falling short for the needs that already exist?  Are key applications being under-served because the tools weren't designed for them?

What's Your Take?

Are similar trends showing up in your experience?

Let's keep the conversation going—reach out at sjetton@m5d.com or connect with me on Linkedin

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.

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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!

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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!

If you’re like most businesses, you’ve got numerous questions about additive manufacturing—perhaps even a few misconceptions, too. You’re wondering: 

• Why should I be excited about adopting additive manufacturing?
• Can it really provide a competitive advantage?
• How would it help solve my customer challenges?
• What if it doesn’t work for me?

We created this webinar to answer these questions and many more.  

In the first of our three-panel discussions, you’ll hear from additive manufacturing leaders who will answer these questions and MORE—all from their own experience. How they started. What they learned. What mistakes to avoid.
You’ll hear from:

• Peter Koostra, Director of Engineering, RE3DTECH
• Kevin Carr, President, MasterGraphics
• David Rosendahl, President, MindFire Inc., Moderator

Watch the webinar recording now to gain insights into:  

• The unexpected reasons organizations are adopting additive manufacturing for a competitive advantage
• How companies start their additive journey (often through diversification), and the surprising lessons learned along the way
• Which approach to additive manufacturing doesn’t work
• Answers to questions that our webinar attendees had about expanding solutions to customers’ challenges 

Over the years, there have been many myths about 3D printing. One of these myths is that it would completely replace injection molding or CNC.  While 3D printing is capable of an incredible range of applications, it doesn't have to replace everything you're currently leveraging.  3D printing serves as a flexible and innovative supplement to your existing technology.

Are you curious about what the actual use cases for 3D printing are and how you can leverage them and get optimal results?

Here's your chance to find out!

Experts from leading 3D manufacturing companies such as MasterGraphics, Re3DTech, Graco, and Enerpac will come together to share their knowledge and secret recipes for success.

Throughout the webinar, the keynote speakers will share with you:

The benefits of introducing more 3D parts into your company mix.
How additive manufacturing can improve your supply chain.
Actual case studies on how people utilize 3D printing for TRUE Additive Manufacturing.

You'll also get a chance to meet and network with seasoned professionals.  

This question should be asked in various business initiatives.  However, I want to ask this question as it relates to additive manufacturing especially in smaller manufacturing companies that have yet to adopt additive manufacturing. 

When just beginning something—be it a journey for improvement or an initiative to ensure you are prepared, I always suggest starting small.  Companies that want to dip their toes into 3D printing have a couple of choices; own their own AM equipment or rely on service bureaus.  Times are also changing.  And those old production processes mean you could be losing your competitive edge by missing out on LARGE cost savings.  

Additive manufacturing can provide significant ROI to small manufacturers by helping:

• Improve their industrial tooling processes
• Produce more high-value, complex, low-run parts
• Create highly customized products for their industry and their customers

Start with a basic step process for additive manufacturing:

1. It starts with an organizational shift.  Generate an additive manufacturing mindset within the organization.
2. Create a roadmap.  Pilot a targeted small area and then scale up.
3. Develop a business case.  Examine impacts of parts from your supply chain and or product life cycle with the use of additive manufacturing.
4. Identify challenges and evaluate whether additive manufacturing fits in your company.

You have to get started with additive manufacturing/3D printing - doing nothing gets you nothing!