Scaling Creativity with Additive Manufacturing

NOVEMber 05, 2024 | Reading time: 5 min

 

In this episode of the Additive Snack Podcast, host Fabian Alefeld sits down with Shawn Zindroski, co-founder and COO of SNL Creative, to explore the fascinating world of additive manufacturing (AM).

With nearly three decades of experience, Shawn brings a wealth of knowledge about the evolution of 3D printing technology and the intricacies of scaling an AM business. This conversation not only traces Shawn’s professional journey but also highlights some of the most exciting projects he’s been involved with, including the groundbreaking Wilson airless basketball. Through their discussion, listeners gain valuable insights into how creativity and innovation fuel the future of manufacturing and what it takes to succeed in the ever-changing AM landscape.

 

Shawn Zindroski’s Journey Into Additive Manufacturing and Founding SNL

Shawn Zindroski’s career in AM began in the late 1990s, during the early days of 3D printing, then known as "rapid prototyping." His first exposure came through a job in one of the first service bureaus spun out of 3D Systems. This hands-on experience in stereolithography and other early technologies laid the foundation for his deep technical understanding of the industry.

Driven by a passion for both technology and creativity, Shawn founded SNL with the goal of bringing innovation to the AM space. His time working with industries like automotive, where precision and aesthetics were equally important, helped shape SNL’s approach. At its core, SNL balances technical expertise with creative problem-solving, pushing the boundaries of what’s possible with AM. Whether producing customized, one-off parts or scaling for mass production, SNL thrives by applying creative solutions to complex manufacturing challenges.

 

Key Challenges and Lessons in Scaling Additive Manufacturing

As SNL took on more high-profile clients, the challenges of scaling AM became increasingly apparent. While AM offers unparalleled flexibility in design and the ability to create intricate parts, scaling it for mass production introduced a new set of hurdles. Shawn candidly shares the difficulties of maintaining both quality and precision when moving from small-scale, one-off prototypes to larger production runs.

One of the primary challenges lies in ensuring consistency across batches. Unlike traditional manufacturing, where processes are often well-established and fine-tuned for high-volume output, AM is still evolving. The complexity of AM machines means that slight deviations in settings or environmental factors can lead to variations in the final product. Shawn points out that even with meticulous planning, print failures or inconsistencies can occur, particularly when running machines overnight or through long production cycles.

In addition to technical challenges, managing client expectations still is crucial. Many manufacturers look at AM as a "magic bullet" for quick and cost-effective production, but Shawn stresses the importance of educating clients on the realities of the process. Whether it's navigating the limitations of current materials or explaining the intricacies of post-processing, clear communication helps clients understand why certain steps are necessary to achieve the desired result. Shawn’s approach to these challenges is rooted in transparency and collaboration, ensuring that every stakeholder is aligned on the project’s goals and potential limitations.

The Wilson Airless Basketball

One of SNL’s most exciting and high-profile collaborations is the production of the Wilson airless basketball — a revolutionary product that showcases the true potential of AM. The project was a milestone not only for SNL but for the AM industry as a whole, as it brought 3D printing technology into the mainstream sports world.

The Wilson airless basketball features an intricate, lattice-like structure that replaces the need for air, maintaining the same bounce and performance as a traditional basketball. Achieving this level of complexity and functionality required an extraordinary amount of collaboration between SNL, Wilson, EOS, and other partners. Shawn highlights that while the ball’s unique design garners attention for its aesthetics, the real innovation lies in the precision and performance standards it had to meet. It wasn’t just about 3D printing a basketball; it was about ensuring it could withstand rigorous use while meeting Wilson’s high expectations for quality and playability.

To produce the ball, SNL had to overcome several technical challenges, such as ensuring uniformity in the lattice structure, perfecting the vapor smoothing process, and applying a consistent dye to achieve the iconic Wilson orange. The project required seamless coordination across different teams and technologies, with each partner contributing specialized expertise. The final product is not only a feat of engineering but also a piece of art, bridging the gap between functional design and consumer appeal.

It also highlights SNL’s role as a key player in taking AM beyond prototyping and into full-scale, real-world production.

Future of Additive Manufacturing: Automation, Robotics, and Sustainability

Looking ahead, Shawn envisions a future where AM continues to evolve with the integration of automation, robotics, and sustainable practices. As AM technology matures, the industry is pushing beyond the limitations of traditional manufacturing by incorporating advanced robotics to streamline production and reduce costs. Automation is a key trend that excites Shawn, particularly in how it can optimize workflows, improve consistency, and enhance scalability in high-volume production environments.

Another area of innovation is the development of conformal cooling and other performance-enhancing tools that offer significant benefits over traditional methods. For instance, custom-made tools with internal cooling channels can dramatically improve efficiency in industries like automotive and aerospace. Shawn believes that as these technologies advance, AM will play an increasingly important role in creating highly functional, customized solutions that deliver better performance.

Sustainability is also becoming a critical focus in the world of AM. Shawn notes that industries across the board are exploring how 3D printing can reduce waste and lower carbon footprints, particularly as more companies seek environmentally friendly alternatives. With the ability to print only the material needed, AM inherently reduces excess, but there’s still more to be done.  

Shawn points to new materials, such as bio-based resins and recycled polymers, that are paving the way for greener production processes. Additionally, SNL is already working on projects involving nanotechnology and material traceability, which not only improve sustainability but also enhance product security by embedding unique digital fingerprints into each component. 

As the AM industry moves forward, Shawn sees a future where manufacturers can create products that are not only more efficient and innovative but also more sustainable and ethical.

Final Thoughts

As AM continues to expand its capabilities, Shawn Zindroski’s insights from nearly three decades in the industry highlight the limitless potential of this technology. From his early experiences with stereolithography to leading groundbreaking projects like the Wilson airless basketball, Shawn has demonstrated the power of innovation, creativity, and collaboration in driving the future of AM.

For businesses considering how to integrate 3D printing into their processes, Shawn’s advice is simple: approach the technology with an open mind and a willingness to experiment. AM can solve a wide range of challenges, from reducing lead times to creating highly customized products, but it requires careful planning and a deep understanding of both its capabilities and limitations. By partnering with experienced AM companies like SNL, businesses can explore how this technology can enhance their product portfolios and improve operational efficiency.

As the industry moves toward greater automation, sustainability, and advanced material science, the future of AM looks brighter than ever. For Shawn and the team at SNL, the journey is just beginning, and they remain committed to pushing the boundaries of what’s possible, one groundbreaking project at a time.

 

Connect with Shawn Zindroski and the Additive Snack Team