• 3DSystems
  • Prosthesis
  • Art and Architecture
  • Volunteer
  • Publications
    • List of Patents
    • Forbes
    • SME - Society of Manufacturing Engineers
    • Investment Casting Institute
    • CNN
    • Engadget
    • Planetary Resources
    • Intel Experience Amazing
    • Washington Post
    • Daily Mail
    • Makezine
    • Fox News Insider
    • Huffington Post
    • Al Jazeera Channel
    • The Verge
    • xzysit
    • 3D Print.com
    • 3D Heals
  • About

ENK'D

  • 3DSystems
  • Prosthesis
  • Art and Architecture
  • Volunteer
  • Publications
    • List of Patents
    • Forbes
    • SME - Society of Manufacturing Engineers
    • Investment Casting Institute
    • CNN
    • Engadget
    • Planetary Resources
    • Intel Experience Amazing
    • Washington Post
    • Daily Mail
    • Makezine
    • Fox News Insider
    • Huffington Post
    • Al Jazeera Channel
    • The Verge
    • xzysit
    • 3D Print.com
    • 3D Heals
  • About

Investment Casting

While some of the most interesting and forward-thinking projects I’ve worked on remain covered under NDA, some of what I can talk about is covered below

QuickCast is a pioneering additive manufacturing investment casting process employed by industry leading companies worldwide. Some aerospace clients have leveraged QuickCast Diamond to help drive some of the most groundbreaking advancements in rocketry seen in the past 50 years. Its influence extends across sectors, from optimizing advanced automotive designs in Formula 1 to transforming energy production methods.

I led the team behind the latest innovations in the QuickCast product line and hold several patents in this space. These innovations include QuickCast Diamond, a single-vector tetrahedral infill structure now widely adopted as an industry standard among aerospace companies, and QuickCast Air, the recently launched smart infill pattern designed to maximize material efficiency when printing investment casting patterns

Silicone Molding

Egg Shell Molding, also known as Digital Silicone Tooling, is an advanced additive manufacturing technique for producing custom and intricate silicone components using ultra-thin, single-use 3D-printed molds.

I contributed to the early conception and on going development of this method across various 3D printing technologies—including SLA, DLP, and MJP—and hold multiple patents in this area.

This method of manufacture has been used to make a wide variety of silicone components and has impacted everything from the prototyping of VR headsets to anatomical models used in surgical simulations.

Soft Goods and Wearables

While some of the most interesting and forward-thinking projects I’ve worked on remain covered under NDA, some of what I can talk about is covered below

My career began with a strong focus on medical devices, where I designed wearable solutions that stabilized injured joints while integrating embedded sensors to provide users with real-time feedback on movement and alignment. These innovations have spanned from custom mouthguards equipped with accelerometers to detect concussions, to simple yet effective silicone straps designed to enhance surgical mask performance.

Throughout my career at 3D Systems, I’ve had the privilege of collaborating with leading manufacturers of soft goods and wearables from around the world, contributing to pioneering projects that merge technology, fashion, and functionality. Partnering with industry leaders such as New Balance, I helped develop flexible midsoles in a wide range of advanced elastomeric materials, while collaborations with visionary designers like Iris Van Herpen and the team at United Nude brought innovative couture concepts to life. Many of these creations have been featured on prestigious international stages, including Milan Fashion Week.

This intersection of bioengineering, health, and fashion continues to inspire my work—driving me to push the boundaries of wearable technology and explore how design and science can converge to improve human experience.

Human Centered Design

Throughout my career, I’ve collaborated with industry leaders from Align to Medtronic and have designed groundbreaking concepts that expand the boundaries of manufacturing technologies. From helping to develop the processes for printing millions of customized dental arches to patenting a process that allows for the creation of complex anatomical models in various silicones, I have contributed to a range of innovative projects that bring previously impossible concepts to life.

Working with groups like Metamason, I helped develop user-specific CPAP masks through mass-produced eggshell molds, and with 3DS Healthcare, I created digital workflows enabling plastic surgeons to pre-plan surgeries with precision.

The footwear industry has always been an exciting space and over the years I have helped with various companies, artists, designers and engineers from across the world to create everything from high end concept shoes to production medical orthotics.

While I’ve collaborated with many other teams, the images and topics shown here represent the few images I am permitted to share. My time with 3D Systems has been a privilege, offering the opportunity to work with global pioneers in design and manufacturing and contribute to advancements that are now transforming industries worldwide


Multi Material Printing

During my time at 3D Systems, I’ve had the opportunity to work with some of the most advanced 3D printing technologies on the market. Leveraging the capabilities of 3D Systems’ MJP printers, I’ve contributed to the development of high-precision medical simulation devices, and surgical models created directly from CT scans, pushing the boundaries of what multijet printing can achieve in the medical field.

Beyond 3DS hardware, I’ve also had the chance to test and push competitive systems like the Stratasys J-series and Mimaki’s full-color printers. This experience has allowed me to explore each printer’s capabilities in terms of resolution, color matching, and gradient precision, expanding the potential applications of these technologies and advancing our understanding of their limits.


Regenerative Medicine

While most of the most interesting work is covered by NDA and cannot be shown yet

My work at 3D Systems has involved collaboration with some of the foremost pioneers in regenerative medicine. I specialize in designing intricate microfluidic structures embedded within complex macro frameworks that mimic various human body systems. I've partnered directly with industry leaders like CollPlant, United Therapeutics, and Volumetric to push forward advancements in microfluidic organ design and manufacturing.

In addition, I’ve collaborated with regenerative tissue teams at 3D Systems to develop complex scaffolds aimed at commercializing applications for soft tissue engineering. While also helping companies like Systemic Bio design microfluidic chips based on human vascular structures.

100% of the most impressive work cannot be shown publicly yet


Mass Production

Leveraging a range of advanced technologies at 3D Systems, I’ve helped pioneer concepts such as Stacked Printing and digitally arrayed investment casting, enabling users to fully utilize the print volume and dramatically improve production efficiency. Using platforms like PSLA, DLP, and SLA, I’ve optimized build parameters and part geometries to achieve production outputs exceeding 6,000 parts per day from a single machine, and I hold several patents in this field.

While some of the most groundbreaking work I’ve contributed to remains covered under NDA, my experience spans the optimization of manufacturing workflows across a wide range of industries and printing technologies—refining processes for everything from cost per part and production speed to mechanical performance and overall reliability.

Digital Texturing

I’ve spent years mastering software such as ZBrush, Substance Painter, Rhino + Grasshopper, Maya, and Photoshop to pioneer digitally textured 3D-printed parts. These textured parts, produced across various 3D printing technologies, have been utilized in multiple industries. At 3D Systems, I've collaborated closely with clients to apply textures directly to printed parts, refining these processes over time.

My work with companies like Adobe’s Substance Painter has focused on developing workflows that enable complex textures to be imported directly into slicers, eliminating the need for heavy mesh files. Additionally, I collaborate with internal software teams to create some of the first user-friendly texturing tools in the additive manufacturing industry.

Hardware Development

Over the years, I’ve had the privilege of collaborating with various hardware teams to design and refine some of 3D Systems' latest SLA, SLS, MJP, DLP, DMP, and PSLA printing platforms. Each platform was the result of a dedicated team of exceptionally talented individuals, all working together to deliver precisely the hardware our customers needed.

Many of the projects I contributed to involved retrofitting hardware, optimizing machine parameters, and making custom firmware tools to meet specific customer and industry needs, ultimately helping to expand our customer base following each product launch.

Regeneratively Cooled Thrust Chamber Concept

I led the design team for the CrCop-42 3D-printed regeneratively cooled thrust chamber, engineered to mount onto an additively manufactured (though unprinted) fuel injector. This thrust chamber serves as a powerful demonstration of how additive manufacturing enables engineers to create highly complex designs. Despite the copper alloy’s melting point being significantly lower than the extreme temperatures within the thrust chamber, the structure is kept intact by circulating cryogenic fuels through the chamber walls, effectively preventing overheating and showcasing the potential of advanced cooling methods in high-stress environments.

Topology Optimization

Together with a variety of software partnerships we explored the cutting edge in topology optimization and mesostructural optimization.

These types of advanced design techniques are mainly used in aerospace applications the strongest and lightest components are critical.

We have also explored the latest 3D-printing and Investment casting techniques in further advance the field.

Most projects cant be shown due to ITAR requirements

Planetary Resources

I lead the design team responsible for the first object to even be printed from a Meteroite.


Planetary Resources, in collaboration with partner 3D Systems, have developed the first ever direct metal print from asteroid metals.


This spacecraft prototype was 3D printed from an actual asteroid that was pulverized, powdered, processed then printed on 3D Systems ProX DMP 320 metals 3D printer. The asteroid was melted under vacuum then gas atomized into powder by Allegheny Technologies, Inc. at their ATI Powder Metals research facility in Pittsburgh, PA.

Thermally Optimized Heat Exchangers

I have led design teams in developing thermally optimized heat exchangers, utilizing advanced software packages like 3DXpert, nTopology, and Rhino + Grasshopper to simulate and build complex designs across a range of metals compatible with Direct Metal Printing (DMP) technologies.

Jet Engine Hot Section

I led the design team behind one of the world's largest and most complex direct metal prints. This jet engine hot section was designed in partnership with leading european aerospace technologists and was conceived to demonstrate the possibilities available with the latest “Supportless” technology developed by the 3D Systems DMP team.

Lobbed Exhaust Mixer

This Lobbed Exhaust Mixer was design and optimized to print with the lightest structures possible. Printed in Incolne on a the 3D Systems ProX320. The DMP component is both easy to print and quick to post process enabling the users to spend more time doing whats fun, and less time cleaning parts.

Ti Golf Club

Cyogenic Manifold Concept

Optomized Box Fan

Designed with the intention of moving a traditionally manufactured metal box fan into the world of additive manufacturing.

The initial customers design would not print with out sever distortion that resulted in an unusable component. The design was re-engineered to minimize the distortion, while at the same time improving overall structural integrity and reducing its mass for improved efficiency.

Investment Casting

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Silicone Molding

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Soft Goods and Wearables

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Human Centered Design

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Multi Material Printing

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Regenerative Medicine

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Mass Production

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Digital Texturing

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Hardware Development

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Regeneratively Cooled Thrust Chamber Concept

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Topology Optimization

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Planetary Resources

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Thermally Optimized Heat Exchangers

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Jet Engine Hot Section

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Lobbed Exhaust Mixer

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Ti Golf Club

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Cyogenic Manifold Concept

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Optomized Box Fan

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