3D Printing | Theory: Going deeper into the Print

In this episode of Big Ideas Only, host Mikkel Svold will dive deeper into the theory and science behind additive manufacturing or 3D printing. Mikkel is joined again by Kristoffer Ryelund Nielsen (former Head of Engineering at the Danish Technological Institute) and Karl Frederik Fischer (PhD, Materials Science) from the Danish Technological Institute.

We will unpack how layer-by-layer manufacturing really works, why powder-bed fusion delivers near-finished parts, how patent expiries reshape the market, and where materials science is pushing the limits from multi-material prints to meta-stable alloys you can’t make any other way.

In this episode, you’ll learn about:

1. Additive vs. subtractive manufacturing, and why “layers” matter.
2. Powder bed fusion with lasers: tiny layers, fine features, and strong parts.
3. What materials get printed today (PA12, 316L, Ti-6Al-4V) and why.
4. How patent expiries drove prices down and access up.
5. Multi-material printing for better cooling, cost and performance.
6. Topology optimization and why design freedom + simulation = lighter parts.
7. Printing in extreme places (ISS, Moon/Mars) and why logistics drive adoption.
8. The realistic future: more availability, faster machines, and targeted high-value parts.

Episode Content
01:39 The basics with additive manufacturing 
03:04 What is powder bed fusions?
10:30 The printing range today 
14:24 Why additive manufacturing is great for weight and thermal/flow 
26:38 First metal prints in space
27:40 Bioprinting in micro-gravity
28:24 Next 5 years with 3D printing
35:08 Start with the problem, not the material list
35:59 Why patent cycles reshape the market 

This podcast is produced by Montanus.