Fabian Alefeld welcomes back Harshil Goel, founder and CEO of Dyndrite, to discuss how current additive manufacturing (AM) qualification practices limit advanced laser powder bed fusion toolpaths by locking variables such as software, machine, strategy, layer height, and material. Harshil reviews MQ, IQ, OQ, and PQ, noting cost and rigidity increase toward part qualification.
They discuss Dyndrite’s roles in multiple America Makes efforts: AI4AM to reduce the specimen counts needed for material allowables (starting with 17-4PH) using improved statistical methods; DeltaQual 2.0 to enable “bracketed qualification” so parameter changes within a defined process window don’t retrigger requalification (including varying layer heights within a part); and Gotham to transfer scalable, qualified parameter approaches across different machines and sizes using materials like Scalmalloy.
Harshil describes “Sasquatch,” a physics-based KPV framework using ratios (e.g., energy density, enthalpy, melt pool dimensions) to bound process windows and increase confidence without relying solely on sensors or simulation, and highlights software and AI accelerating DOE and parameter iteration with a target program timeline of about two years.
01:34 What Dyndrite Builds
02:11 Why Qualification Blocks Innovation
03:58 IQ OQ PQ MQ Explained
08:22 PQ Locks Everything Down
09:00 America Makes Program Overview
09:57 AI4AM Materials Allowables
12:39 Process Windows Not Fixed Params
14:57 Delta Qual 2 Bracketed Qual
17:38 Partners Sensors And Confidence
19:25 Sasquatch New KPVs
25:33 Gotham Scaling Across Machines
27:07 Future Less PQ More Reuse
28:39 Industry Impact Of Faster Qual
29:52 Customer Owned Parameters
30:54 Additive As Moat
32:13 Microstructure Driven IP
33:12 Selling Machine Control
34:31 Breaking Vendor Silos
35:36 Two Year Timeline
37:57 Risks And Adoption
41:23 Software As Glue
42:11 AI Accelerated DOE
45:34 Math Meets Empiricism
49:48 Future Outlook Wrap
