QuickCast is a pioneering additive manufacturing investment casting process employed by industry leading companies worldwide. Some aerospace clients have leveraged QuickCast Diamond to help drive some of the most groundbreaking advancements in rocketry seen in the past 50 years. Its influence extends across sectors, from optimizing advanced automotive designs in Formula 1 to transforming energy production methods.

I led the team behind the latest innovations in the QuickCast product line and hold several patents in this space. These innovations include QuickCast Diamond, a single-vector tetrahedral infill structure now widely adopted as an industry standard among aerospace companies, and QuickCast Air, the recently launched smart infill pattern designed to maximize material efficiency when printing investment casting patterns

Egg Shell Molding, also known as Digital Silicone Tooling, is an advanced additive manufacturing technique for producing custom and intricate silicone components using ultra-thin, single-use 3D-printed molds.

I contributed to the early conception and on going development of this method across various 3D printing technologies—including SLA, DLP, and MJP—and hold multiple patents in this area.

This method of manufacture has been used to make a wide variety of silicone components and has impacted everything from the prototyping of VR headsets to anatomical models used in surgical simulations.

Throughout my career at 3D Systems, I’ve had the privilege of collaborating with wearable designers from around the world, working on pioneering projects that blend technology, fashion, and function. Partnering with industry giants like New Balance, I’ve contributed to developing flexible midsoles, and I’ve collaborated with visionary fashion designers such as Iris Van Herpen and United Nude to bring forward-thinking couture to life. Many of these creations have been showcased on prestigious international stages, including Milan Fashion Week, and some of the manufacturing workflows I helped innovate were even featured on Project Runway.

Starting my career with a strong focus on medical devices, I initially designed wearable solutions that not only stabilized injured joints but also integrated embedded sensors to provide users with real-time feedback on joint alignment and movement.

As my expertise in soft goods and wearables expanded, I transitioned to the 3D Systems regenerative medicine team. Here, I contributed to designing custom foam structures that simulate the properties of various human soft tissues, exploring the lines between wearable devices and implantable devices.

This intersection of bioengineering, health, and fashion continues to drive my work, pushing the boundaries of what’s possible in wearable technology.

Throughout my career, I’ve collaborated with industry leaders from Align to Medtronic and have designed groundbreaking concepts that expand the boundaries of manufacturing technologies. From helping to develop the processes for printing millions of customized dental arches to patenting a process that allows for the creation of complex anatomical models in various silicones, I have contributed to a range of innovative projects that bring previously impossible concepts to life.

Working with groups like Metamason, I helped develop user-specific CPAP masks through mass-produced eggshell molds, and with 3DS Healthcare, I created digital workflows enabling plastic surgeons to pre-plan surgeries with precision.

The footwear industry has always been an exciting space and over the years I have helped with various companies, artists, designers and engineers from across the world to create everything from high end concept shoes to production medical orthotics.

While I’ve collaborated with many other teams, the images and topics shown here represent the few images I am permitted to share. My time with 3D Systems has been a privilege, offering the opportunity to work with global pioneers in design and manufacturing and contribute to advancements that are now transforming industries worldwide

During my time at 3D Systems, I’ve had the opportunity to work with some of the most advanced 3D printing technologies on the market. Leveraging the capabilities of 3D Systems’ MJP printers, I’ve contributed to the development of high-precision medical simulation devices, and surgical models created directly from CT scans, pushing the boundaries of what multijet printing can achieve in the medical field.

Beyond 3DS hardware, I’ve also had the chance to test and push competitive systems like the Stratasys J-series and Mimaki’s full-color printers. This experience has allowed me to explore each printer’s capabilities in terms of resolution, color matching, and gradient precision, expanding the potential applications of these technologies and advancing our understanding of their limits.

My work at 3D Systems has involved collaboration with some of the foremost pioneers in regenerative medicine. I specialize in designing intricate microfluidic structures embedded within complex macro frameworks that mimic various human body systems. I've partnered directly with industry leaders like CollPlant, United Therapeutics, and Volumetric to push forward advancements in microfluidic organ design and manufacturing.

In addition, I’ve collaborated with regenerative tissue teams at 3D Systems to develop complex scaffolds aimed at commercializing applications for soft tissue engineering. While also helping companies like Systemic Bio design microfluidic chips based on human vascular structures.

100% of the most impressive work cannot be shown publicly yet

Leveraging various technologies at 3D Systems, I have helped pioneer concepts like 'Stacked Printing,' enabling users to maximize their use of the print volume for enhanced efficiency. Printers such as the PSLA270 and Figure 4 utilize pixel-based printing technology to image the entire build area simultaneously, significantly increasing print speed over legacy systems and making true mass manufacturing a reality.

With systems like the PSLA270, I have optimized build parameters and part geometries to achieve production outputs of over 6,000 parts per day from a single machine and hold several patents in this space.

I’ve spent years mastering software such as ZBrush, Substance Painter, Rhino + Grasshopper, Maya, and Photoshop to pioneer digitally textured 3D-printed parts. These textured parts, produced across various 3D printing technologies, have been utilized in multiple industries. At 3D Systems, I've collaborated closely with clients to apply textures directly to printed parts, refining these processes over time.

My work with companies like Adobe’s Substance Painter has focused on developing workflows that enable complex textures to be imported directly into slicers, eliminating the need for heavy mesh files. Additionally, I collaborate with internal software teams to create some of the first user-friendly texturing tools in the additive manufacturing industry.

Over the years, I’ve had the privilege of collaborating with various hardware teams to design and refine some of 3D Systems' latest SLA, SLS, MJP, DLP, DMP, and PSLA printing platforms. Each platform was the result of a dedicated team of exceptionally talented individuals, all working together to deliver precisely the hardware our customers needed.

Many of the projects I contributed to involved retrofitting hardware, optimizing machine parameters, and making custom firmware tools to meet specific customer and industry needs, ultimately helping to expand our customer base following each product launch.

I led the design team for the CrCop-42 3D-printed regeneratively cooled thrust chamber, engineered to mount onto an additively manufactured (though unprinted) fuel injector. This thrust chamber serves as a powerful demonstration of how additive manufacturing enables engineers to create highly complex designs. Despite the copper alloy’s melting point being significantly lower than the extreme temperatures within the thrust chamber, the structure is kept intact by circulating cryogenic fuels through the chamber walls, effectively preventing overheating and showcasing the potential of advanced cooling methods in high-stress environments.

Together with a variety of software partnerships we explored the cutting edge in topology optimization and mesostructural optimization.

These types of advanced design techniques are mainly used in aerospace applications the strongest and lightest components are critical.

We have also explored the latest 3D-printing and Investment casting techniques in further advance the field.

Most projects cant be shown due to ITAR requirements

I lead the design team responsible for the first object to even be printed from a Meteroite.

Planetary Resources, in collaboration with partner 3D Systems, have developed the first ever direct metal print from asteroid metals.

This spacecraft prototype was 3D printed from an actual asteroid that was pulverized, powdered, processed then printed on 3D Systems ProX DMP 320 metals 3D printer. The asteroid was melted under vacuum then gas atomized into powder by Allegheny Technologies, Inc. at their ATI Powder Metals research facility in Pittsburgh, PA.

I have led design teams in developing thermally optimized heat exchangers, utilizing advanced software packages like 3DXpert, nTopology, and Rhino + Grasshopper to simulate and build complex designs across a range of metals compatible with Direct Metal Printing (DMP) technologies.

I led the design team behind one of the world's largest and most complex direct metal prints. This jet engine hot section was designed in partnership with leading european aerospace technologists and was conceived to demonstrate the possibilities available with the latest “Supportless” technology developed by the 3D Systems DMP team.

This Lobbed Exhaust Mixer was design and optimized to print with the lightest structures possible. Printed in Incolne on a the 3D Systems ProX320. The DMP component is both easy to print and quick to post process enabling the users to spend more time doing whats fun, and less time cleaning parts.

Designed with the intention of moving a traditionally manufactured metal box fan into the world of additive manufacturing.

The initial customers design would not print with out sever distortion that resulted in an unusable component. The design was re-engineered to minimize the distortion, while at the same time improving overall structural integrity and reducing its mass for improved efficiency.