Marco: Ken, you’ve had quite a journey in 3D printing. Could you share how you got started?

Ken: “I actually stumbled into the industry! My journey began when a friend, who was operating a small service bureau, invited me to join him after his business partner stepped away. At the time, I knew almost nothing about 3D printing, so I dove in, learning CAD, engineering, and all the technical aspects on the job. Those early years were hands-on, with our small team handling everything from cleaning parts to business development. Over time, I grew passionate about the industry, especially as I saw the potential for 3D printing to disrupt traditional manufacturing.”

Marco: Could you share how you got started and how Forecast 3D became the company it is today?

Ken: “We were then acquired by Forecast 3D, which started as a urethane casting company in 1994 and later added 3D printing as part of the process to create master patterns for casting. In 1996, we adopted SLA technology and began offering 3D printing services directly. In those days, additive manufacturing was still emerging, but we saw an opportunity to grow alongside the technology. Over the years, we gradually incorporated SLS, FDM, and other technologies, aligning with the evolving demands of our clients.

Then, in 2019, GKN Additive acquired Forecast 3D, which was a natural step that solidified our shift toward high-volume additive manufacturing. Joining GKN Additive enabled us to expand our resources and scale while focusing on 3D printing’s unique role in production. It’s been a journey of growth and adaptation, and I’m proud of how far we’ve come.

Eventually, we focused heavily on powder bed fusion, particularly MJF and SLS. We now have 50 powder bed printers, producing between 100,000 and 200,000 parts monthly for customers across multiple industries.

Today, GKN Additive and Forecast 3D primarily serve verticals where additive manufacturing brings high value, including automotive, consumer goods like footwear, unmanned systems, and industrial components. Each industry has unique requirements, from rapid iteration in drones and robotics to durable, customized parts in automotive and consumer products, where AM’s flexibility and scalability make a real difference.”

“Eventually, we focused heavily on powder bed fusion, particularly MJF and SLS. We now have 50 powder bed printers, producing between 100,000 and 200,000 parts monthly for customers across multiple industries.”

Marco: Could you share insights on your collaboration with Forward AM and TPU01? How has TPU01 been transformative for GKN Additive?

Ken: “Ultrasint® TPU01 has become a cornerstone material for us. Early on, we evaluated different TPU options and chose Forward AM’s TPU01 due to its broad application potential and superior properties. It has proven itself in challenging projects and offers the flexibility, durability, and surface finish that our clients value. Working with Forward AM has allowed us not just to use a material but to co-develop solutions that integrate with our existing processes.”

Marco: Let’s talk about some use cases. Studio LINQ and General Motors both partnered with Forecast 3D for high-stakes projects. Could you walk us through these?

Ken: “For Studio LINQ, we produced a unique, ergonomically optimized cushioning system for footwear using HP’s MJF and TPU01. The innovative design incorporates a lattice structure that disperses impact while offering arch support, which would have been nearly impossible with traditional manufacturing. The project was a testament to the precision and repeatability of MJF and our collaborative approach.

In the case of General Motors, we were tasked with producing 60,000 spoiler closeout seals in just five weeks to avoid delaying vehicle deliveries. Working with Forward AM for TPU01 and our other partners, we developed a process to deliver high-quality parts quickly. This project showcased the scalability and reliability of 3D printing for automotive applications, which is crucial as the industry looks to AM for solutions that bridge traditional and additive manufacturing.”

Marco: How has your experience with TPU01 impacted your approach to new projects?

Ken “Our work with TPU01 has highlighted the importance of designing specifically for additive manufacturing. From lattice structures to unique finishing processes, TPU01 opens new possibilities. We now actively collaborate with clients to ensure designs are optimized for additive, especially for flexible materials. This shifts the conversation from just producing parts to creating tailored solutions that best leverage the advantages of AM.

In addition, Forward AM’s support in troubleshooting and scaling up applications has been invaluable. They help us navigate any roadblocks, from design and post-processing challenges to providing data like skin-contact safety, which reassures clients considering TPU for consumer goods.”

“In the case of General Motors, we were tasked with producing 60,000 spoiler closeout seals in just five weeks to avoid delaying vehicle deliveries. Working with Forward AM for TPU01 and our other partners, we developed a process to deliver high-quality parts quickly.“

Marco: As 3D printing moves towards serial production, what does the future hold for GKN Additive?

Ken: “We’re committed to a model that balances innovation with sustainable growth. Unlike the early days, when some anticipated a rapid “hockey-stick” growth curve, we now recognize the steady progress AM requires to truly integrate into traditional manufacturing. Our focus remains on scaling while keeping our processes flexible to adapt to client needs across sectors like automotive, consumer goods, and unmanned systems.”

Marco: Any closing thoughts?

Ken: “Collaboration is essential in our industry, and the relationship with Forward AM has been invaluable. The industry’s future depends on partnerships that push the boundaries of what’s possible while keeping grounded in realistic expectations for AM’s capabilities and potential.”