The present and future of AM according to EOS’ Gregory Hayes

Things are constantly changing within the world of 3D printing. Companies are coming and going. Technology is popularized one day and seemingly irrelevant the next. This is not the case for Germany’s EOS, a 35-year-old industry leader. We recently caught up with Gregory Hayes, the Senior Vice President of Global at EOS’ Additive Minds, at RAPID + TCT, in Los Angeles, to understand how the company has managed to stay ahead during turbulent times, and the global implications of the technology.

Prior to joining EOS, Greg was working with the Netherlands Organisation for Applied Scientific Research (TNO). He has a PhD in material science – a domain in which he believes a lot of problems are solved, and in which possibilities are unlocked.

From prototyping to production

During our conversation, Greg emphasized the EOS longevity and its evolution over the years – highlighting the transition from an exploratory phase to a focus on production, reliability, and repeatability.

As part of this, the company has been focusing on the longevity of its systems, and upgrades, as opposed to ‘system bells and whistles.’ For example, the latest EOS M 290 dual laser system is a derivative of the EOS M 280, which is a derivative of the EOS M 270. “Companies that are using the EOS M 290 now in production can easily delta qualify the new EOS M 290 and get up and running on a similar platform that they know and works well.”

The EOS M 400 platform, a cornerstone of EOS’ production capabilities, is more than 10 years old, with the company installing more than 500 of them, globally, to-date. This system has also recently seen significant upgrades, including an improved gas flow – optimizing it for better and more homogeneous properties, and for production generally.

EOS has also increased the laser power of the EOS M 300-4 – taking the quad laser system from 400-watt lasers to 4 x one-kilowatt lasers in the EOS M 300-4 1kW metal AM system. The increase in power results in an increase in scanning speed, and also enables the melting of materials like copper and other metals.

“Everything that we are working on, in one form or another, stems from this transition from a prototyping industry to a production machine,” he said. This shift is crucial for industries such as aerospace, where the use of copper in heat exchanger applications is becoming increasingly significant. “Copper development is huge in all heat exchanger applications, of course. And I would loosely consider a rocket engine as a type of heat exchanger application, right?”

New North American Center of Excellence

One of the major recent initiatives by EOS is the establishment of a new training center located in Novi, Michigan – aimed at addressing workforce development needs. The center, which falls under the company’s Additive Minds Academy brand, will have its grand opening on August 1, and will provide basic and advanced training, service training, and certification programs in collaboration with standardized training bodies like ASTM.

The center’s goal is to equip operators with the necessary skills to maximize the potential of EOS machines – focusing on how to optimize and maintain the systems. The facility will cater to a diverse audience, including existing customers needing additional training, new customers ramping up their operations, and students from university collaborations aiming to graduate as certified operators within additive manufacturing. The center will support government programs, including those under the Department of Defense – providing specialized training to meet the stringent requirements of these sectors.

The work that EOS is doing in North America is part of a broader trend toward the global adoption of 3D printing technologies in the region. As industries worldwide recognize the potential of additive manufacturing, EOS’ innovations and training initiatives are helping to shape a more resilient and efficient global supply chain. “There’s been a notable increase in production discussions with our customers… Defense is one such area.”

The ability to produce parts locally and on demand reduces dependency on traditional manufacturing hubs, thereby mitigating risks associated with geopolitical tensions and supply chain disruptions. “Additive can play a role in solving a lot of [these] problems, not just design and function.”

The impact of digital design tools

The convergence of engineering capabilities and production capabilities in 3D printing is a noteworthy development. “For the first time in the last 12 to 15 years… the engineering teams and the design capabilities are on par with and equally matched with the production capabilities,” said Greg. This alignment has been facilitated by advanced software tools such as nTop and Autodesk, which have democratized access to high-level design capabilities.

These tools enable engineers to create complex, optimized designs that were previously difficult or impossible to manufacture. “Computational design tools have been around for quite some time, but they’re now more prevalent and user-friendly,” he said. The synergy between these advanced design capabilities and reliable production systems unlocks new potential for innovative applications across various industries, from aerospace to consumer products.

Global competition

In terms of competing Chinese 3D printing companies, Greg does not view them as a threat, but rather with a sense of excitement, stating that he is very much paying attention. He sees the entry of these companies as a catalyst for the industry – injecting energy and possibilities that drive innovation and competitiveness – resulting in industry-wide growth. “We are at a moment in an emerging technology industry where we need to grow the pie larger.”

He recognizes the strengths that Chinese companies bring to the table, including potentially lower price points and different manufacturing capabilities. However, he believes that EOS and other established players have their own advantages, such as proven reliability, quality, and extensive experience.

“This is the race we always wanted to run. Let’s do it. This industry has been asking for legitimacy, for globalization, and for manufacturing to ramp up,” he said, viewing the competition as a sign of the industry’s maturity and a call to further elevate the company’s game. He believes that the entrance of more players, including those from China, will ultimately lead to a more professional and robust industry. “The better players you have on the field, the better the whole industry will become.”

Boring is beautiful

During our conversation, Greg introduced an interesting perspective on the future of additive manufacturing – emphasizing the importance of scalable, less glamorous applications such as 3D printing blocky, boring parts that are usually cast but with long lead times. “But you can print it, and you can solve the problem on the table.” This focus on practical, high-volume applications is where he sees some of the most significant growth potential. For instance, the ability to produce simple, functional parts that are essential for maintaining supply chains and meeting procurement demands can have a tremendous impact. “Boring is beautiful, man. Boring is beautiful.”

This pragmatic approach to additive manufacturing highlights the technology’s potential to address real-world challenges efficiently – ensuring that the industry remains resilient and responsive to the needs of various sectors, and encapsulating the importance of focusing on practical solutions that drive the broader adoption and success of 3D printing technology.