Nexa3D is the maker of ultrafast 3D printers geared for functional prototyping, bridge production, and on demand manufacturing.
We are seemingly in a golden era for human ingenuity, with the convergence of many megatrends driven by AI. Following your acquisition of Essentium, what does the present moment mean for you?
I've been preparing for this moment for over four and a half decades. Manufacturing is central to a thriving economy, and I witnessed what I consider the greatest transfer of wealth from the U.S. to countries like China during GE's peak. This shift involved moving factories overseas in search of lower costs, leading to a significant loss of know-how and the foundation of self-sustainability. Manufacturing is crucial for national security, democracy, and self-sufficiency. The pandemic exposed the fragility of global supply chains, with shortages of essential products like personal protection equipment.
Today, we are in the midst of a manufacturing renaissance. Supply chain resilience has become a top priority for CEOs, alongside business continuity. The way businesses now consider costs has evolved, factoring in availability, freight, and other complexities. With the convergence of advanced technologies enabling hyper-local and digital manufacturing, we are on the brink of a new era, promising a resurgence in manufacturing jobs, community revitalization, and economic growth.
What convinced you that there was still more to achieve in the 3D printing space?
I considered many other ventures but realized that the vision I started pursuing decades ago—of a replicator-like technology that could produce fully formed parts quickly—was still unfulfilled. Despite progress, the potential of 3D printing hadn’t been fully realized, and there remained significant opportunities for innovation. About seven years ago, I gathered with a few people to decide if it was worth founding another company. Our conclusion was that the world didn't need just another 3D printing company; it needed one that was exponentially better—faster, more affordable, and capable of meeting the conservative expectations of traditional manufacturers. We didn’t want to offer incremental improvements; our aim was to deliver groundbreaking advancements that could genuinely transform the industry.
The shift towards new manufacturing methods is reshaping the industry. What specific segments is Nexa3D targeting, and why have you chosen those areas as priorities?
We are particularly focused on segments like aftermarket spare parts. This market faces a real, unmet need as companies often have to maintain supply for parts long after production ends, sometimes over a decade. Original molds are often lost or misplaced globally, and quick access to injection molding machines may not be available. Addressing these challenges through digital inventory and ensuring manufacturing continuity presents a significant opportunity.
Beyond spare parts, we're developing hybrid solutions that integrate with existing manufacturing setups. Having been in the industry for decades, I’ve learned that additive manufacturing won’t entirely replace traditional methods but can complement them. We have pioneered "freeform injection molding," where a dissolvable resin withstands traditional injection molding processes. This approach allows companies to blend new and familiar methods, easing the transition to more advanced manufacturing while maintaining reliability.
Speed and efficiency are critical in the world of 3D printing. With the launch of the XiP Pro, how does it stand out in terms of speed, and can you illustrate its advantages with a relatable example?
The XiP Pro represents a leap in speed, much like the difference between dial-up internet and 5G. Back when dial-up was the norm, it was slow but revolutionary. Now, with 5G, you’d never go back. The XiP Pro brings similar progress to 3D printing, being up to 20 times faster than the next competitor, depending on material and design complexity. For many parts, production can be completed in just five to ten minutes, with larger pieces taking up to an hour.
Our speed and precision enable us to deliver parts with surface finishes, tolerances, and mechanical properties that match traditional injection molding. This capability is critical because manufacturers need to trust that the quality will meet their standards. Speed, reliability, and lower overall costs make XiP Pro an appealing choice for companies seeking to scale production without sacrificing quality.
Given the rapid technological advances and market changes, what are the major challenges that keep you up at night, especially in terms of risks for Nexa3D?
There are many external challenges that could derail progress, some of which we've already experienced in recent years, including a tough economic climate and geopolitical tensions. These challenges have stressed supply chains and strained business continuity. However, such disruptions can also be catalysts for rethinking business models and accelerating the shift towards more resilient, self-sufficient manufacturing. Cybersecurity is also a significant concern as more manufacturing processes become digital and interconnected. Powerful technologies in the wrong hands can have adverse consequences. For example, we have seen instances where 3D printing technology was used to create weapons, sparking public controversy. Issues like protecting intellectual property and ensuring the security of design files as they move online will be critical. Addressing these challenges is essential for building trust in digital manufacturing and ensuring its continued growth.
By 2030, what role do you see 3D printing playing in the broader manufacturing landscape, and how will it integrate with other technologies?
By 2030, 3D printing will be a standard part of manufacturing cells, working alongside robotics, injection molding, and CNC machining. It will play a crucial role in producing aerospace components, medical devices, transportation parts, and even footwear, integrating seamlessly into existing manufacturing environments. The companies that thrive will be those that integrate AI deeply into their operations. 3D printing will not replace traditional manufacturing but will complement it, providing flexibility where it is most needed. Factories of the future will use 3D printers alongside injection molding machines and robotic arms, enabling a more flexible, responsive production line. This approach will unlock new design possibilities and create a more adaptive manufacturing landscape.
