Show Notes
Title
3D Printing in Theory | Going Deeper into the Print
Introduction
In this episode of Big Ideas Only, host Mikkel Svold dives deeper into the theory and science behind additive manufacturing. Mikkel is joined again by Kristoffer Ryelund Nielsen (former Head of Engineering) and Karl Frederik Fischer (PhD, Materials Science) from the Danish Technological Institute.
They unpack how layer-by-layer manufacturing really works, why powder-bed fusion delivers near-finished parts, how patent expiries reshape the market, and where materials science is pushing the limits — from multi-material prints to meta-stable alloys you can't make any other way.
In this episode, you'll learn about:
- Additive vs. subtractive manufacturing — and why "layers" matter.
- Powder bed fusion with lasers: tiny layers, fine features, and strong parts.
- What materials get printed today (PA12, 316L, Ti-6Al-4V) and why.
- How patent expiries drove prices down and access up.
- Multi-material printing for better cooling, cost, and performance.
- Topology optimization and why design freedom + simulation = lighter parts.
- Printing in extreme places (ISS, Moon/Mars) and why logistics drive adoption.
- Meta-stable alloys enabled by ultra-fast solidification — and new industrial use cases.
- The realistic future: more availability, faster machines, and targeted high-value parts.
Episode Content
01:39 Kristoffer explaining the basics with additive manufacturing
02:25 From clay "sausages" to computer-controlled layers
02:36 The materials on the table
03:04 Karl explains powder bed fusion
07:07 What has changed in the printing machine
10:30 The printing range today
14:24 Why additive manufacturing is great for weight and thermal/flow
25:24 Why powders and micro-gravity don't mix; wire-based metal printing wins on ISS
26:38 First metal prints in space
27:40 Bioprinting in micro-gravity
28:24 Next 5 years with 3D printing
35:08 Start with the problem, not the material list
35:59 Why patent cycles reshape the market