Brad Keselowski Returns with More Thoughts on the Future of Additive Manufacturing

[Image: Matt Sullivan/Getty Images]

NASCAR is a fan of new technology – anything that can make cars drive faster or more smoothly, or help to construct them more efficiently. One Formula One team that has been especially involved in the use of 3D printing is Team Penske, which has been in action since the 1960s and has won 174 NASCAR victories. Team Penske driver Brad Keselowski has 27 career victories of his own on the top circuit, but driving isn’t his only interest – he’s also become involved in advanced manufacturing. As it happens, those interests often overlap.

Keselowski ran his own truck team, Brad Keselowski Racing, for a decade before shutting down in 2017. At that time, he alluded to a new business venture, which turned out to be Keselowski Advanced Manufacturing, a North Carolina-based business that specializes in hybrid additive manufacturing and CNC technology. Keselowski first learned about additive manufacturing from Joe Hoffman, who ran the manufacturing department at Team Penske. Hoffman left the team to start his own company, FiberWorks, a carbon fiber engineering and manufacturing company, and Keselowski began to do his own research into advanced manufacturing.

He admits that at first, he was “skeptical” and “cynical” about the technology.

“Additive manufacturing has been around for a while, but it’s been in plastic,” he says. “There’s something to be said for printing something in plastic. The reality is, plastic parts don’t very often go on race cars or spaceships and things of that nature. There’s only so much you can do with plastic. Plastic is great for a desk toy. It’s not great for an engine of a race car. I had thought of additive manufacturing off the plastic brand, per se. There’s a metal component that’s much newer and has much less maturity that is really the revolutionary topic in my mind.”

When he talks about metal additive manufacturing, however, Keselowski gets excited. He believes that the technology is going to “improve the human experience in a significant way.”

[Image: Tony Gutierrez/AP]

“Metal additive manufacturing, to me, I don’t want to oversell it, but it feels like the new Internet,” he says. “It’s the technology that’s going to take us not just to space, like we’ve been, but space like going to Mars. It’s the technology that’s going to make us live healthier and longer. If you look at some of the medical tools that are out there, they are made possible only by 3D printing out of metal.”It’s the technology that’s going to enable things like nuclear fusion because of the doors it opens in cooling and exotic materials that were previously closed have somewhat prohibited nuclear fusion from developing. This technology is potentially going to open those doors. And that’s just the start. We don’t know how big it’s going to be. We’re limited by our own imagination, much like the early days of the Internet.”

He points to additive manufacturing’s potential for using exotic materials, as well as the complex parts, such as passageways and lattices. The greatest example of what 3D printing can accomplish, he adds, is the GE Aviation LEAP fuel nozzle, which just this week saw its 30,000th part produced. He’s also intrigued by what the technology can offer the medical industry.

Many people fear advanced technology as a threat to manufacturing jobs, but in Keselowski’s opinion, 3D printing is just the opposite – it’s going to open up many more doors in the manufacturing industry. Different doors, perhaps, but still doors.

“There’s going to be a wave of high-end jobs coming up for this sector,” he says. “We’re looking for people that are four-, six-, eight-year college grads because the technology is hard to do and requires an advanced understanding. You might still call them blue-collar jobs, but they’re really high-end blue-collar jobs. It’s almost a new color of manufacturing job.”

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[Source: SportTechie]

 

3D Printing News Briefs: September 22, 2018

In today’s 3D Printing News Briefs, we’ve got the speaker lineup for next month’s NAMIC Global Additive Manufacturing Summit in Singapore. Prusa and Cincinnati Incorporated are both releasing new 3D printing materials, and 3D Center is collaborating with 3YOURMIND to launch a 3D printing platform for the Scandinavian market. A British car manufacturer turns to Stratasys 3D printing for prototyping purposes, and a student used reverse engineering and 3D printing to redesign a Nintendo 64 joystick system.

2018 NAMIC Global Additive Manufacturing Summit Speakers

On October 17th and 18th, the 2018 Global Additive Manufacturing Summit, conducted by Singapore’s National Additive Manufacturing Innovation Cluster (NAMIC), will be held, and co-located as part of Industrial Transformation ASIA-PACIFIC. Hosted by NTUitive, the summit, which is said to be the country’s largest gathering of additive manufacturing experts, will highlight key AM opportunities and developments in multiple applications, such as aerospace, automotive, biomedical, building and construction, marine, and transportation.

This is the last week to purchase your ticket at the early bird rates. After seeing the line-up of speakers coming to the event, this is an event you definitely won’t want to miss. Some of the speakers include Dr. Behrang Poorganji, the Head of Materials Development for GE Additive: Apis Cor’s Anna Cheniuntai, R&D and Business Development; Kelvin Wee, the APAC Sales Director for Materialise; and Professor Paul C. Ho, with the Department of Pharmacy at the National University of Singapore. You can register for the 2018 NAMIC Global Additive Manufacturing Summit here.

Prusa Releasing In-House 3D Printing Filament

Fresh off the multi-material upgrade for its Prusa i3 MK3/MK2.5, Prusa has more good news – this week, the company released its new filament, Prusament, which is made entirely in-house. CEO and Founder, Josef Průša, said that the company was not happy with the over-exaggerated quality and specs that “most filament companies claim but don’t deliver,” which continued to cause its users to have issues poor print quality and jams.

“So we built a factory and just started to sell our own filament,” Průša told 3DPrint.com. “It took us over a year but we have something pretty special. We guarantee 20µm precision and every spool is traceable on our website, where you can see the full inspection report. I believe we are the only one to do this and hope to set a precedent.”

Check out the sample spool of Prusament for yourself – you’ll see that Prusa isn’t messing around.

Cincinnati Incorporated Launches New Carbon Fiber Material

Cincinnati Incorporated has developed a new material for its SAAM that is ideal for custom tooling and fixture applications. The carbon fiber resin creates a high strength-to-weight ratio and superior surface finishes.

Another company with a new 3D printing material launch this week is Cincinnati Incorporated (CI) – it just released a new carbon fiber resin material for its SAAM (Small Area Additive Manufacturing) 3D printing system. Because it’s been reinforced with carbon fiber, the lightweight, impact-resistant material is durable, stiff, and has low warping, along with accurate parts featuring advanced inter-layer adhesion results. It also has excellent surface finish, making it a good choice for applications in assembly, CMM, CNC fixtures, custom tooling, and has a very high strength-to-weight ratio.

 

 

 

Morgan Motor Company Turns to Stratasys 3D Printing for Prototyping

Family-owned British motor car manufacturer Morgan Motor Company is no stranger to 3D printing, and recently turned to the technology again for help with prototyping on the factory floor. In order to get rid of the endless talks with suppliers and lower the time to market, the company, which manufactures roughly 1,000 vehicles per year, invested in a Stratasys Fortus 250mc from Tri-Tech 3D, a Stratasys reseller in the UK.

“Since the introduction of 3D printing, using the Stratasys Fortus 250mc, Morgan have been able to try more daring designs within research and development,” said Tom Morris, a CAD technician with Morgan Motor Company. “It’s given us the opportunity to take these designs, trial them early on, giving us physical samples, which essentially cuts out the whole quoting process of liaising with suppliers, delivering these parts back to Morgan. Morgan are a low volume vehicle manufacturer, so the ability to be able to design parts on CAD, 3D print them, and take them to the shop floor at a very quick rate is vital to our success as a business.”

Watch the video below to learn more:

Fixing Nintendo 64 Joystick with Reverse Engineering and 3D Printing

California Polytechnic (Cal Poly) student and retro video gaming fan Nam Le was tired of having to find replacement controller joysticks for Nintendo 64 systems – a common problem many Nintendo fans have dealt with. So he took matters into his own hands, and contacted 3D Hubs for help fixing the problem. Le ended up reverse engineering the nearly 20-year-old components, 3D printing them, and redesigning the entire joystick system. It took him three months to disassemble the original controller, measure the components, and design them in CAD – a very impressive task, as he’d only ever taken a basic 3D modeling introduction class.

He determined that the joystick’s whole assembly would wear down over time, causing part failure, and designed the new components so that they were very sturdy and easy to replace. Le 3D printed the gear teeth and housing with Visijet M3 Crystal material, and 3D Hubs manufactured his redesigned joystick out of Nylon PA12 material on an HP Multi Jet Fusion 3D printer.

“Generally, harder materials won’t be worn by materials of a lower hardness,” Le explained about his material choice. “The result is having only one part wear compared to every old component wearing. Every once in a while the stick will have to be replaced, but it takes a longer time to wear and is a better cheap alternative than buying a new controller.”

Six months in, Le’s 3D printed prototype joystick controller shows no signs of breaking.

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3D Printing News Briefs: August 7, 2018

We’re starting things off on today’s 3D Printing News Briefs with a little business and a little software, before moving on to more cool 3D printing projects and products. NextFlex has announced its Project Call 4.0, and we’ve got a closer look at a 3D print filament recycling system that was introduced at the Barcelona Maker Faire. OnShape has announced the latest updates to its CAD system. A university student 3D printed a car muffler, and Printable Science presents its 3D printed safety razor.

NextFlex Project Call 4.0

Last month, the NextFlex consortium, one of the leaders in the Manufacturing USA network, announced the award recipients of $12 million in funding for the latest round of its extremely successful Project Call program for Flexible Hybrid Electronics (FHE) innovations. This week, the consortium announced the $10 million funding round for its Project Call 4.0, which has a “very diverse scope of needs” that represent gaps in capabilities and technology in multiple application areas. Proposals should focus on several manufacturing thrust areas (MTA), such as flexible battery integration, FHE device encapsulation, evaluating and developing connectors for e-textiles and FHE devices, and advanced 3D electrical design software, among others.

“NextFlex’s Project Call process has proven to be extremely successful. We continuously tackle member-identified FHE manufacturing challenges, and with 31 projects already underway from three previous project calls, we expect this to garner even more interest from the FHE community,” said Dr. Malcolm J. Thompson, the Executive Director of NextFlex. “Topics in Project Call 4.0 build upon successful developments and learning from our previous project calls.”

OUROBOROS 3D Printing Recycling System

The Barcelona Maker Faire was held earlier this summer, and one of the many innovations on display at the event included an all-in-one recycling system for 3D printing called the OUROBOROS. The system shreds used plastic and extrudes the material into a 3D printable filament. According to YouTube user Joan Cullere, the OUROBOROS system includes a prototype shredder with a 24 V motor that’s almost completely 3D printed itself.

In addition to the economic and compact shredder prototype, the OUROBOROS 3D printing recycling system features a user-friendly filament extruder with better cooling, a new spooling system, and an optimized filament path. To see the new system for yourself, check out the video below.

Onshape System Updates

Modern CAD platform Onshape introduced the premium edition of its software in May, and delivers automatic upgrades to the system every three weeks. The latest updates, from July 12 and August 1, include many new improvements to the Onshape CAD system.

For instance, the July 12 update introduced a feature for adjusting the line thickness in drawings, which allows users to define the thickness for tangent, hidden, and visible edges. This update also added a new Drawing Properties panel icon, which replace the wrench icon and includes several new features. The August 12 update made it possible for users to change existing parts or assemblies to a revision, which means every stage of the workflow can be changed. In addition, users can now enjoy significant rebuild time improvements in the system’s complex multi-part Sheet Metal Part Studios. The next updates should arrive on August 23rd.

3D Printed Car Muffler

University student and YouTube user Cooper Orrock was inspired by another maker’s DIY project – a duct tape and cardboard car muffler – to make his own 3D printed version. He designed the two-component automotive part and 3D printed it in plastic; then, with the help of some friends, he prepared the part for installation on a vehicle. This included clearing out some of the holes on the rim of each part so it could be screwed together, and removing the original muffler from the car.

“Part of me thinks that it could possibly melt just because of all the heat from the engine and stuff, but part of me thinks it could work,” Orrock said.

To see if his prediction came true, check out the video below.

3D Printed Safety Razor

Printable Science, which creates “all the science that’s fit to print’ according to its Patreon page, creates all sorts of nifty 3D printed projects, like a socket nut driver, a mini hacksaw handle, and a USB microscope stand. Now, it’s moved on to a 3D printed, four part plastic safety razor.

“Forget the dollar shave club… forget paying shipping and handling… 3D print your own safety razor and be part of the 29 cent shave club,” a member of Printable Science said on the YouTube video.

He explained that the basic design of the safety razor has been mostly unchanged for about 150 years, and that with the design for this razor, you can make your own for just 19 cents. However, this isn’t the first 3D printed razor we’ve seen – in fact, the Gillette Company filed a patent for a 3D printable razor cartridge a few years ago, and was also one of the co-creators of a challenge to design a 3D printed razor handle. To see how Printable Science’s 3D printed plastic safety razor compares, check out the video below.

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3D Printing News Briefs: June 26, 2018

We have plenty of business, material, and 3D printer news to share with you in today’s 3D Printing News Briefs. 3D printing led to increased savings for GM over the last two years, which is now increasing its use of the technology as a result. ExOne is saying goodbye to one CEO and hello to another, while Polymaker announces a global distribution arrangement with Nexeo Solutions and CollPlant receives R&D project approval in Israel. The US Patent and Trademark Office will be hosting its annual Additive Manufacturing Partnership Meeting this week, and RP Platform has announced a rebrand and a new AI software platform. Finally, the UK’s National Centre for Additive Manufacturing has decided to add Digital Metal’s binder jetting technology to its portfolio.

GM Increasing Use of 3D Printing at Plants

Zane Meike, AM lead at GM’s Lansing Delta Township assembly plant, holds a common 3D printed tool used to align engine and transmission vehicle identification numbers. [Photo: Michael Wayland]

According to Dan Grieshaber, the Director of Global Manufacturing Integration for General Motors (GM), most of the company’s factories have 3D printers, which are used to build accessories and tools for workers. A $35,000 3D printer at GM’s Lansing Delta Township assembly plant has actually helped save the company over $300,000 over two years: it’s used to make multiple items, such as part hangers, socket covers, and ergonomic and safety tools. A common tool used to align engine and transmission vehicle identification numbers cost $3,000 to buy from a third party, but is less than $3 to 3D print at the factory. Realizing that these kinds of savings can add up quickly, GM is increasing the use of 3D printing – part of its new Manufacturing 4.0 processes – at its plants in order to help streamline operations.

“We’re quickly evolving, creating real value for the plant. This will become, as we progress, our footprint. We’ll have this in every one of our sites,” Grieshaber said.

Grieshaber also said that GM is working to standardize 3D printing, as well as share best practices across all of its global plants.

ExOne Welcomes New CEO

The ExOne Company, which provides 3D printers and 3D printed products, materials, and services to its industrial customers around the world, has announced that its CEO, James L. McCarley, is departing the company, effective immediately, to pursue other interests and opportunities; he will be assisting the company in transitioning his responsibilities to the new CEO. ExOne’s Board of Directors has also announced who the new CEO will be – S. Kent Rockwell, the company’s Executive Chairman, who has served in the position in previous years. Rockwell’s new title is effective immediately.

“On behalf of our Board and management team, I would like to thank Jim for his efforts and wish him all the best in his future endeavors,” said Rockwell.

Polymaker Makes Distribution Arrangement with Nexeo Solutions

Shanghai-based 3D printing material producer Polymaker has entered an arrangement with chemicals and plastics distributor Nexeo Solutions, Inc., also based in Shanghai. Nexeo will be a global distributor for three new materials in the Polymaker Industrial line, but plans to introduce more of its materials over the rest of the year. C515 is an advanced polycarbonate (PC) filament that has excellent toughness and a low warping effect, while C515FR is a flame retardant PC with high impact resistance. SU301 is a polyvinyl alcohol (PVA)-based polymer that’s water soluble and was developed as a support material for FFF 3D printers.

Paul Tayler, the Vice President of EMEA at Nexeo Solutions, said, “Expanding our portfolio to include industrial grade filaments from Polymaker Industrial gives our customers access to a wider range of filaments that solve new 3D printing challenges and meet the demands of manufacturers. Industrial customers benefit from Nexeo Solutions’ access to world leading plastic producers coupled with additive manufacturing technical expertise.”

CollPlant Receives R&D Project Approval

Two years ago, regenerative medicine company CollPlant received funding from Israel’s Ministry of Economy for its research in developing collagen-based bioinks for 3D printing tissues and organs. CollPlant, which uses its proprietary plant-based rhCollagen (recombinant human collagen) technology for tissue repair products, has now announced that the Israel Innovation Authority (IIA) has approved a grant to finance the continued development of its rhCollagen-based formulations intended for use as bioinks. Terms of the grant require CollPlant to pay royalties to the IIA on future sales of any technology that’s developed with the use of the funding, up to the full grant amount. The total project budget is roughly $1.2 million (NIS 4.2 million), and the IIA will finance 30%, subject to certain conditions.

“In addition to providing immediate non-dilutive funding, this grant from the Israel Innovation Authority represents an important validation of our BioInk technology and its market potential. With the recent opening of our new cGMP production facility in Rehovot, Israel, we are well positioned to meet growing demand for our BioInk and tissue repair products. We are grateful to the IIA for this recognition,” said CollPlant CEO Yehiel Tal.

Additive Manufacturing Partnership Meeting Hosted by US Patent and Trademark Office

For the last several years, the US Patent and Trademark Office (USPTO) has been hosting the Additive Manufacturing Partnership Meeting, and this year’s meeting takes place tomorrow, June 27th, from 1 to 5 PM at the USPTO headquarters inside the Madison Building in Alexandria, Virginia. The USPTO will be seeking opinions from various participants at the informal meeting, which is really a forum for individual 3D printing users and the USPTO to share ideas, insights, and personal experiences.

“We value our customers and the feedback provided from individual participants is important in our efforts to continuously improve the quality of our products and services,” the USPTO meeting site reads. “Your willing participation in this informal process is helpful in providing us with new insights and perspectives.”

Scheduled speakers at this year’s meeting are coming from CIMP-3D, HRL, Kansas State University, Lawrence Livermore Laboratories, and the NextManufacturing Center, and an RSVP is required to attend the AM Partnership Meeting.

RP Platform Launches New AI Software and Rebrand

London-based RP Platform, which provides customizable workflow automation software for industrial 3D printing, is launching a new software platform, which will use AI for the first time to automate 3D printing production. With customers in over 30 countries, the company is one of the top automation software providers for industrial 3D printing. In addition to its software launch, RP Platform has also announced that, as it continues to expand its software capabilities to target AM end part production, it is rebranding, and has changed its name to AMFG.

“We want to help companies make their 3D printing processes much smoother so that they can produce more parts with greater visibility and less effort. And we have more exciting releases to our software over the coming months that will further enhance our production automation capabilities,” said Keyvan Karimi, the CEO of AMFG.

“Ultimately, we’re creating a truly autonomous manufacturing process for industrial 3D printing. For us, this means taking manufacturing to a new era of production. The launch of our new software, as well as our company rebrand, fully reflects this vision going forward.”

NCAM Installing a Digital Metal 3D Printer

The National Centre for Additive Manufacturing (NCAM) in the UK, headquartered at the Manufacturing Technology Centre (MTC) in Coventry, has decided to add the unique binder jetting technology developed by Digital Metal to its large range of advanced manufacturing equipment, and will soon be installing one of its high-precision metal 3D printers – which are not available anywhere else in the UK. The 3D printer will be available for use by NCAM’s member companies, and other organizations, who are interested in testing the capabilities of Digital Metal’s proprietary binder jetting technology.

Dr. David Brackett, AM Technology Manager at the NCAM, explained, “The Digital Metal binder jetting technology falls into the category of ‘bind-and-sinter AM’, where a multi-stage process chain incorporating sintering is required to achieve full density. It’s a very fast technology that can create complicated and highly detailed designs, and there is potential for wider material choice than with AM processes that use melting. We are delighted to be able to offer this to the companies we work with.”

The Digital Metal 3D printer will be operational later this summer, and NCAM personnel are already training with it to ensure they can operate it efficiently and safely.

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Jay Leno’s Contribution to Auto Part 3D Printing

It is well known that Jay Leno is an avid car enthusiast and has a world-renowned collection of nearly 300 vehicles. What isn’t as well known is that his team does their own car repair and utilizes 3D printing for replacement parts. It can be difficult and costly finding parts for vintage cars that ended final production many years ago.  Most car collectors don’t have enough vehicles to justify experimenting with 3D part design and production. Specialty replacement parts providers are few and far between. Waiting for a few parts can tie up a garage repair bay for a long time. Jay Leno is showing the auto industry how to address these issues with 3D printing. Companies and individuals engaged in the classic car business are eligible for R&D tax credits.

The Research & Development Tax Credit

Enacted in 1981, the now permanent Federal Research and Development (R&D) Tax Credit allows a credit that typically ranges from 4%-7% of eligible spending for new and improved products and processes. Qualified research must meet the following four criteria:

  • Must be technological in nature
  • Must be a component of the taxpayer’s business
  • Must represent R&D in the experimental sense and generally includes all such costs related to the development or improvement of a product or process
  • Must eliminate uncertainty through a process of experimentation that considers one or more alternatives

Eligible costs include US employee wages, cost of supplies consumed in the R&D process, cost of pre-production testing, US contract research expenses, and certain costs associated with developing a patent.

On December 18, 2015, President Obama signed the PATH Act, making the R&D Tax Credit permanent. Beginning in 2016, the R&D credit can be used to offset Alternative Minimum Tax, for companies with revenue below $50MM and for the first time, pre-profitable and pre-revenue startup businesses can obtain up to $250,000 per year in payroll taxes and cash rebates.

The large auto manufacturers and their suppliers have experimented with 3D part design but to date have not yet evolved to volume production.  Leno serves as an additional auto parts design incubator and an example the auto industry can learn from.

Other Classic Car Part Designer Examples

Porsche

Porsche is among the leaders in manufacturing specialized high-performance sports vehicles, and has been doing so for nearly 90 years. Porsche is integrating 3D printing to keep their older model vehicles running and eliminate expensive tooling and storage costs for numerous classic Porsche models. Cars such as the 1986 Porsche 959 where only 292 were built require special parts that do not exist anymore and would take a series of complex tooling to acquire a necessary part. With Porsche’s digital fabrication processes, they can simply scan and print a single part instead of producing numerous small run expensive components that require entire tooling mechanisms. Porsche is currently utilizing 3D printing to print eight other components from plastic or steel and is testing whether 3D printing can be used to reproduce many more components.

Mercedes-Benz

Mercedes-Benz is a global automobile marquee known for their luxury vehicles and trucks that has been a consistent adopter of the latest technology to improve upon their past, present and future product lines. Mercedes-Benz can essentially print any part for any car they’ve ever built just as long as they have the schematics or part in hand to duplicate it. Customers are closer now to having access to a large catalog of replacement or custom parts that Mercedes can print and ship in a short amount of time. The utilization of 3D printing removes the overhead of machining expensive parts and tools while setting up a market to sell what were once very expensive parts, for a fraction of the cost.

Freshmade 3D

Freshmade 3D in Ohio is a team of highly skilled individuals with extensive experience in additive manufacturing, materials and processes, industrial design and reverse engineering. They strive to provide precious antique and valuable classic car parts that become increasingly difficult to find every day through the use of 3D printing methods, and are poised to lead the industry in serving restoration and custom automotive markets. With few alternatives for finding a classic car replacement part, Freshmade 3D gives enthusiasts a valuable option to use additive manufacturing to engineer quality parts or prototypes that would be much more expensive if the parts were to be machined. Freshmade 3D offers a wide range of materials and small-medium scale manufacturing that will satisfy most car part needs.

PartWorks

PartWorks is a 3D printing and CNC machining company out of Georgia that uses the latest technology to deliver the best manufactured parts for many of the leading industries. PartWorks has become especially adept in the vintage car sector where they are capable of engineering obsolete and custom parts that cannot be found in production today. PartWorks is unique because they utilize precision laser scanners, 3D printers, CNC machining and injection molds/stamps that allow their customers the options of having the part made in house or offering an open format file of a 3D model that can be printed or edited by the customer themselves.

GRYP

GRYP is a French startup that is using 3D printing to create classic car parts on-demand in an attempt to reduce restoration costs. Their goal is to allow collectors to restore their vintage cars at a consistent and affordable cost to continue the prestigious heritage of such vehicles. GRYP works with numerous automobile clubs and associations, spare parts distributors, and local 3D printing companies in an attempt to integrate large scale 3D printing not only to the classic car sector but to the automotive industry as a whole.

Conclusion

The world had enjoyed Jay Leno’s humor for many years. Now he’s bringing his expertise and creativity to provide design leadership for the automotive industry while having his own fun. Even though Leno retired from late night public television, he still continues his on-camera appearances with his own YouTube channel called Jay Leno’s Garage, dedicated to 3D printing and cars, and has garnered more than 2 million subscribers as he spreads the benefits of utilizing 3D printing.

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Charles Goulding & Ryan Donley of R&D Tax Savers discuss automotive 3D printing.