THE COOL PARTS SHOW

Episodes

8 Cool Parts From Formnext 2024: The Cool Parts Show #78

Peter Zelinski | Additive Manufacturing

End-use parts found at Formnext this year address various aspects of additive's advance, notably AM winning on cost against established processes.

3D Printing Enables a Larger "Sweet Spot" Relative to This Golf Club's Size: The Cool Parts Show #77

Stephanie Hendrixson | Additive Manufacturing

Cobra Puma Golf's Limit3D iron uses 3D printed stainless lattices to remove weight from the interior so that it can be reintroduced with tungsten inserts that lower the center of gravity. The combination offers a smaller, sleeker club head with the forgiveness of a larger one.

Cranial Implant 3D Printed From Hydroxyapatite Ceramic: The Cool Parts Show #76

Stephanie Hendrixson | Additive Manufacturing

Cranial implants are typically made from titanium or PEEK; in this episode of The Cool Parts Show, we look at how implants made from a bioceramic can improve osseointegration and healing.

Preassembled Turbojet Engine, 3D Printed in One Build: The Cool Parts Show #75

Stephanie Hendrixson | Additive Manufacturing

Turbojet engines typically consist of hundreds or thousands of parts, but this engine — 2023 winner of The Cool Parts Showcase for Best Proof of Concept — was 3D printed as just two pieces, with the monolithic rotor embedded inside the stationary engine shell.

3D Printed Capo for Banjo Made With Binder Jetting not MIM: The Cool Parts Show #74

Peter Zelinski | Additive Manufacturing

New market, no mold tooling needed: Additive manufacturing via binder jetting enables a maker of guitar capos to expand to serve banjo players as well.

How 3D Printing Aids Sustainability for Semiconductor Equipment: The Cool Parts Show Bonus

Peter Zelinski | Additive Manufacturing

Hittech worked with its customer to replace fully machined semiconductor trays with trays made via DED by Norsk Titanium. The result is dramatic savings in tool consumption and material waste.

3D Printed Seal for Geothermal Power: The Cool Parts Show #73

Peter Zelinski | Additive Manufacturing

Plugging a hole is a complex challenge when it’s a well for geothermal power. Additive manufacturing produces a shape-changing stainless steel seal for high-temperature applications deep underground.

3D Printed Titanium Replaces Aluminum for Unmanned Aircraft Wing Splice: The Cool Parts Show #72

Peter Zelinski | Additive Manufacturing

Rapid Plasma Deposition produces the near-net-shape preform for a newly designed wing splice for remotely piloted aircraft from General Atomics. The Cool Parts Show visits Norsk Titanium, where this part is made.

3D Printed PEEK Spine Implants in Production: The Cool Parts Show Bonus

Stephanie Hendrixson | Additive Manufacturing

Curiteva is using Fused Strand Deposition to produce two different lines of FDA-cleared spine implants. We visited the company’s Huntsville, Alabama, facility to learn more.

3D Printed NASA Thrust Chamber Assembly Combines Two Metal Processes: The Cool Parts Show #71

Peter Zelinski | Additive Manufacturing

Laser powder bed fusion and directed energy deposition combine for an integrated multimetal rocket propulsion system that will save cost and time for NASA. The Cool Parts Show visits NASA’s Marshall Space Flight Center.

Ultra-Complex 3D Printed Scaffolds Enable Cell Growth: The Cool Parts Show #70

Peter Zelinski | Additive Manufacturing

Perhaps the ultimate surface-area challenge is in bioengineering: creating structures that can grow sufficient cells within a compact volume to be effective for leading-edge medical treatments. The Southwest Research Institute develops bioreactor scaffolds that could only be made using 3D printing.

Variable Resistance Valve Trim Achieves Lead Time Reduction Through AM: The Cool Parts Show #69

Stephanie Hendrixson | Additive Manufacturing

Baker Hughes is realizing shorter lead times and simplified manufacturing through powder bed fusion to produce valve trims previously assembled from many machined metal parts.

Aircraft Ducts 3D Printed in Composite Instead of Metal: The Cool Parts Show #68

Peter Zelinski | Additive Manufacturing

Eaton’s new reinforced PEKK, tailored to aircraft applications, provides a cheaper and faster way to make ducts compared to formed aluminum.

This 3D Printed Part Makes IndyCar Racing Safer: The Cool Parts Show #67

Stephanie Hendrixson | Additive Manufacturing

The top frame is a newer addition to Indycar vehicles, but one that has dramatically improved the safety of the sport. We look at the original component and its next generation in this episode of The Cool Parts Show.

Introducing The Cool Parts Show ALL ACCESS

Peter Zelinski | Additive Manufacturing

Subscribe for early access to new episodes plus exclusive extra video segments offering more about each part.

3D Printed Lattice for Mars Sample Return Crash Landing: The Cool Parts Show Bonus

Peter Zelinski | Additive Manufacturing

NASA Jet Propulsion Laboratory employs laser powder bed fusion additive manufacturing plus chemical etching to create strong, lightweight lattice structures optimized to protect rock samples from Mars during their violent arrival on earth.

This Drone Bird with 3D Printed Parts Mimics a Peregrine Falcon: The Cool Parts Show #66

Stephanie Hendrixson | Additive Manufacturing

The Drone Bird Company has developed aircraft that mimic birds of prey to scare off problem birds. The drones feature 3D printed fuselages made by Parts on Demand from ALM materials.

8 Cool Parts From Formnext 2023: The Cool Parts Show #65

Peter Zelinski | Additive Manufacturing

New additive manufacturing technologies on display at Formnext were in many cases producing notable end-use components. Here are some of the coolest parts we found at this year’s show.

3D Printed Ductile Spikes for Better Sound Quality: The Cool Parts Show Bonus

Stephanie Hendrixson | Additive Manufacturing

Work on 3D printing flexible metal bellows has led to other applications, including the development of ductile spikes that sit between a speaker and the surface below to help limit vibration and isolate the audio equipment.

Flexible Bellows Made Through Metal 3D Printing: The Cool Parts Show #64

Stephanie Hendrixson | Additive Manufacturing

Can laser powder bed fusion create metal parts with controlled flexibility? We explore an example in this episode of The Cool Parts Show.

Understanding PEKK and PEEK for 3D Printing: The Cool Parts Show Bonus

Stephanie Hendrixson | Additive Manufacturing

Both materials offer properties desirable for medical implants, among other applications. In this bonus episode, hear more from Oxford Performance Materials and Curiteva about how these companies are applying PEKK and PEEK, respectively.

FDA-Approved Spine Implant Made with PEEK: The Cool Parts Show #63

Stephanie Hendrixson | Additive Manufacturing

Curiteva now manufactures these cervical spine implants using an unusual 3D printing method: fused strand deposition. Learn how the process works and why it’s a good pairing with PEEK in this episode of The Cool Parts Show.

Airless Basketball Shows Promise of 3D Printed Lattices: The Cool Parts Show Bonus

Peter Zelinski | Additive Manufacturing

Successfully matching the performance of a standard basketball demonstrates the control possible over the mechanical properties of digital materials.

3D Printed Lattices Replace Foam for Customized Helmet Padding: The Cool Parts Show #62

Peter Zelinski | Additive Manufacturing

“Digital materials” resulting from engineered flexible polymer structures made through additive manufacturing are tunable to the application and can be tailored to the head of the wearer.

3D Printed Preforms Improve Strength of Composite Brackets: The Cool Parts Show Bonus

Stephanie Hendrixson | Additive Manufacturing

On this episode, we look at a pin bracket for the overhead bin of an airplane made in two composite versions: one with continuous fiber 3D printed reinforcements plus chopped fiber material, and one molded from chopped fiber alone.

3D Printed "Evolved Structures" for NASA Exoplanet Balloon Mission: The Cool Parts Show #61

Peter Zelinski | Additive Manufacturing

Generative design creates stiff, lightweight brackets for EXCITE mission monitoring planets orbiting other stars. The Cool Parts Show visits Goddard Space Flight Center.

More Affordable Suture Anchors 3D Printed from PEKK: The Cool Parts Show #60

Stephanie Hendrixson | Additive Manufacturing

Selective laser sintering (SLS) of polyether ketone ketone (PEKK) is being used to produce medical implants that are more cost effective and perform better than their conventional counterparts. We highlight fasteners known as suture anchors in this episode of The Cool Parts Show.

Micro Robot Gripper 3D Printed All at Once, No Assembly Required: The Cool Parts Show #59

Peter Zelinski | Additive Manufacturing

Fine control over laser powder bed fusion achieves precise spacing between adjoining moving surfaces. The Cool Parts Show looks at micro 3D printing of metal for moving components made in one piece.

Durable, Waterproof 3D Printed Casts: The Cool Parts Show #58

Stephanie Hendrixson | Additive Manufacturing

Recovering from an injury with an ActivArmor cast means that patients can exercise, bathe and live life while they heal. We get a firsthand look at the solution in this episode of The Cool Parts Show.

3D Printed Cutting Tool for Large Transmission Part: The Cool Parts Show Bonus

Peter Zelinski | Additive Manufacturing

A boring tool that was once 30 kg challenged the performance of the machining center using it. The replacement tool is 11.5 kg, and more efficient as well, thanks to generative design.

3D Printed Metal Filters Protect Circuit Breakers from Explosion: The Cool Parts Show #57

Stephanie Hendrixson | Additive Manufacturing

New high-voltage circuit breakers from Schneider Electric make use of 3D printed metal filters to protect people and equipment in the event of an overload. Binder jetting provided both the geometric complexity and price point needed for these parts.

3D Printed Valve Part Protects Pipes by Preventing Cavitation: The Cool Parts Show #56

Peter Zelinski | Additive Manufacturing

The Fisher Cavitrol Hex trim from Emerson divides the fluid flow into numerous parallel streams thanks to geometry made possible through additive manufacturing.

3D Printed Conveyor Mat Aids Automation: The Cool Parts Show #55

Peter Zelinski | Additive Manufacturing

Additive manufacturing for long, flexible sections of brush material? On this episode of The Cool Parts Show, how a continuous DLP system provides the answer for a component critical to vibratory automation systems.

3D Printed Replacement Clamp for an F-16 Aircraft: The Cool Parts Show #54

Stephanie Hendrixson | Additive Manufacturing

3D printing is a valuable addition to sustainment programs, but only if printed parts can be qualified as fast and flexibly as they can be made. In this episode of The Cool Parts Show, we look at the clamp that won the Air Force’s Approval Sprint Challenge designed to address this need.

Rekkie AR Ski Goggles Made Possible With 3D Printing: The Cool Parts Show #53

Stephanie Hendrixson | Additive Manufacturing

When the electronics enclosure key to these AR goggles proved difficult to mold, 3D printing allowed the inventors to keep the complexity — while also making improvements for assembly and user experience.

Drones Take Flight with Metal and Polymer 3D Printed Parts: The Cool Parts Show Bonus

Stephanie Hendrixson | Additive Manufacturing

Drones produced by Cobra Aero now incorporate many 3D printed parts made through laser powder bed fusion and Multi Jet Fusion processes.

3D Printed Brake Panel for the Rail Industry: The Cool Parts Show #52

Stephanie Hendrixson | Additive Manufacturing

In this episode of The Cool Parts Show, laser powder bed fusion simplifies the manufacturing of air brake panels for light rail systems made by Wabtec.

3D Printed Cold Plate for an Electric Race Car: The Cool Parts Show #51

Stephanie Hendrixson | Additive Manufacturing

An unconventional lattice design and biomimicry are key to the performance of this fluid-cooled heat exchanger for a battery-powered race car.

Robot Deposition Makes Giant Industrial Mixer Blade: The Cool Parts Show Bonus

Peter Zelinski | Additive Manufacturing

Wire arc additive manufacturing produces a large component formerly made through casting, and allows for redesign of its internal cooling geometry.

500-Pound Replacement Part 3D Printed by Robot: The Cool Parts Show #50

Peter Zelinski | Additive Manufacturing

Our biggest metal cool part so far: Wire arc additive manufacturing delivers a replacement (and upgrade) for a critical bearing housing on a large piece of industrial machinery.

It's Shark Week on The Cool Parts Show

Stephanie Hendrixson | Additive Manufacturing

In this bonus episode, we dive into biomimicry and discuss how shark denticles are being used for research as well as Cool Parts.

3D Printed Putter Tailored to the Golfer: The Cool Parts Show #49

Peter Zelinski | Additive Manufacturing

An engineering student in South Africa used metal and polymer 3D printing in tandem to create a putter customized to the individual golfer’s swing.

3D Printed Ceramic Mug: The Cool Parts Show #48

Peter Zelinski | Additive Manufacturing

MadeXBinary applies additive manufacturing to clay. The company achieves automated production of aesthetically pleasing kitchenware through digital pottery.

3D Printed Metal Component for CNC Machining Center: The Cool Parts Show #47

Peter Zelinski | Additive Manufacturing

Machine tool maker DMG MORI improved this coolant delivery adapter by making the part through additive manufacturing instead of machining. One of the viewer-chosen winners of The Cool Parts Showcase.

8 Cool Parts From RAPID+TCT 2022: The Cool Parts Show #46

Peter Zelinski | Additive Manufacturing

AM parts for applications from automotive to aircraft to furniture, in materials including ceramic, foam, metal and copper-coated polymer.

3D Printed Brackets Secure Fuel for Nuclear Power: The Cool Parts Show #45

Peter Zelinski | Additive Manufacturing

Can additive manufacturing improve the design of nuclear power plants? These steel brackets are the first step.

Custom Canine Wheelchair From Carbon Fiber-Reinforced PP: The Cool Parts Show #44

Stephanie Hendrixson | Additive Manufacturing

A dog with a condition that affects her mobility gets a custom 3D printed wheelchair in this episode of The Cool Parts Show, enabled in part by a new polypropylene filament.

3D Printed Heat Exchanger Uses Gyroids for Better Cooling | The Cool Parts Show #43

Peter Zelinski | Additive Manufacturing

Replacement heat exchanger for a helicopter is half the size and delivers 4× the cooling, thanks to a geometry that could only be made via additive manufacturing.

Prototyping Is More Than Printing: The Cool Parts Show Bonus

Peter Zelinski | Additive Manufacturing

We hear from students who carried out other steps, beyond the 3D printing, that went into evaluating a complex metal AM component.

3D Printing for Better Flame From a Gas Turbine Swirler: The Cool Parts Show #42

Peter Zelinski | Additive Manufacturing

A Penn State gas turbine researcher turns to additive manufacturing graduate students to help face the challenge of swirler optimization.

3D Printed Composite Bracket Versus Machined Steel: The Cool Parts Show #41

Stephanie Hendrixson | Additive Manufacturing

Can a 3D printed composite bracket work as well as one machined from steel? Can it also be faster to make and cheaper to produce? In this episode of The Cool Parts Show we explore a new way of manufacturing a bracket for a helicopter door hinge, and similar small parts today made from metal.

3D Printed Concrete Is Key to This Smart Wall: The Cool Parts Show #40

Stephanie Hendrixson | Additive Manufacturing

The SkyBAAM cable-driven 3D printer creates opportunities for embedded functionality in concrete, as demonstrated in this episode of The Cool Parts Show.

3D Printed Tool for Machining Electric Vehicle Motors: The Cool Parts Show #39

Peter Zelinski | Additive Manufacturing

Additive manufacturing achieves a large-diameter cutting tool light enough for fast, precise machining of the motor housing’s stator bore.

3D Printed Magnets: The Cool Parts Show #38

Stephanie Hendrixson | Additive Manufacturing

Is it possible to 3D print a magnet? In this episode of The Cool Parts Show, we learn how magnets have been printed successfully at Oak Ridge National Lab, and the implications this has for energy, material conservation and supply chains.

An X-Ray View of Lattices and String Lasting: The Cool Parts Show Bonus

Stephanie Hendrixson | Additive Manufacturing

One recent cool part concealed most of its complexity. Take a look inside in this bonus episode.

Customizable, Recyclable Shoes with 3D Printed Platform: The Cool Parts Show #37

Stephanie Hendrixson | Additive Manufacturing

A 3D printed TPU platform is the key to both comfort and sustainability for these custom heels manufactured on demand.

8 Cool Parts From Formnext 2021: The Cool Parts Show #36

Peter Zelinski | Additive Manufacturing

The world’s leading trade show for industrial 3D printing returned as an in-person event. Among all the additive manufacturing technology showcased at the show, we also found our most amazing batch of cool parts so far.

3D Printed Turbine Blades for More Efficient Power Generation: The Cool Parts Show #35

Peter Zelinski | Additive Manufacturing

Blades made through additive manufacturing promise to let turbines run hotter, and therefore generate more power without increasing in size.

The Cool Pen Show! (The Cool Parts Show Bonus Episode)

Peter Zelinski | Additive Manufacturing

3D printing provides a means of economical U.S. production for a low-cost product.

Reshoring Manufacturing With 3D Printing: The Cool Parts Show #34

Peter Zelinski | Additive Manufacturing

Wet-dry vacuum maker shifts to additive manufacturing for first entirely U.S.-made product, a jackhammer accessory. More U.S. production to come via 3D printing.

Flight Simulator Made Through Large-Scale 3D Printing: The Cool Parts Show #33

Peter Zelinski | Additive Manufacturing

Our biggest cool part so far! Printing this massive structure in one piece saves cost and time for L3Harris.

8 Cool Parts From RAPID+TCT 2021: The Cool Parts Show #32

Peter Zelinski | Additive Manufacturing

North America’s largest AM trade show resumed! Here are some of the coolest cool parts we found.

Cool Parts In Space!

The Cool Parts Show has long had a fascination with AM for space. Revisit some of our episodes to find out what AM brings to the final frontier.

3D Printed Headgear that Can Take a Hit: The Cool Parts Show #31

Stephanie Hendrixson | Additive Manufacturing

A custom helmet made via Multi Jet Fusion has allowed Sarah Piersanti to get back to practicing jiu-jitsu without fear of damaging her cochlear implant.

Lightweight Combustion Chamber for 3D Printed Rocket Engine: The Cool Parts Show #30

Peter Zelinski | Additive Manufacturing

An engine for repeated trips to the moon is 3D printed in just three pieces from a metal matrix composite combining aluminum for weight saving with ceramic for high-temperature performance.

Hi-Fi 3D Printed Speaker Cabinet: The Cool Parts Show #29

Stephanie Hendrixson | Additive Manufacturing

The Hylixa high-fidelity speaker has an internal geometry and footprint designed for optimal sound that could only be realized through 3D printing. How Node Audio developed and produces this product.

Reusable, 3D Printed Copper Filter: The Cool Parts Show #28

Stephanie Hendrixson | Additive Manufacturing

In this episode of The Cool Parts Show, we learn how controlled porosity obtained through binder jetting can be applied to build metal filters capable of trapping — and even eliminating — virus particles.

Lighter, Better-Performing Brake Rotor From 3D Printing: The Cool Parts Show #27

Peter Zelinski | Additive Manufacturing

Additive manufacturing with an aluminum/ceramic composite enables a brake rotor with one-third the weight and five times the heat transfer of a typical rotor. We talk to the inventor on this episode of The Cool Parts Show.

3D Printed Air Duct Based on Fluid Dynamics: The Cool Parts Show #26

Stephanie Hendrixson | Additive Manufacturing

Air ducts are ubiquitous, but are they all as efficient as they need to be? Computational fluid dynamics informed the redesign of this 3D printed air duct — made to serve a 3D printer.

3D Printed Scapula Customized for Patient: The Cool Parts Show #25

Peter Zelinski | Additive Manufacturing

A patient treated for a tumor of the shoulder blade was able to preserve full use of the arm thanks to an implant tailored to the precise form of the original scapula and made through electron beam melting.

Autonomous Underwater Vehicle With 3D Printed Hull: The Cool Parts Show #24

Peter Zelinski | Additive Manufacturing

Our first episode of The Cool Parts Show from inside a 3D printer! Big Area Additive Manufacturing (BAAM) produces exterior components of a robot submarine and changes how this AUV is marketed.

3D Printed Parts on the Mars Perseverance Rover: The Cool Parts Show #23

Peter Zelinski | Additive Manufacturing

The Perseverance parts made through additive manufacturing are extreme examples of lightweighting. We have replicas of the 3D printed parts that were sent to Mars.

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3D Printed Animal Enrichment Device: The Cool Parts Show #22

Stephanie Hendrixson | Additive Manufacturing

The Cool Parts Show goes to the zoo to learn about a 3D printed enrichment device being used to challenge and engage meerkats, birds, foxes and more in this bonus episode.

What Do These Flip Flops Say About Manufacturing's Future?: The Cool Parts Show #21

Stephanie Hendrixson | Additive Manufacturing

These 3D printed flip-flops are an example of mass customization, but they also hint at manufacturing's more sustainable, circular future. Find out why in this episode of The Cool Parts Show.

Micro 3D Printing for Tiny Connectors: The Cool Parts Show #20

Peter Zelinski | Additive Manufacturing

Microscale additive manufacturing offers an alternative to micromolding and micromachining. On this episode of The Cool Parts Show, 3D printed electrical connectors are our smallest cool part yet.

Generative Design Improves Micromobility FUV: The Cool Parts Show #19

Peter Zelinski | Additive Manufacturing

Arcimoto’s lightweight “Fun Utility Vehicle” gets even lighter thanks to parts that could only come from additive manufacturing. On this episode of The Cool Parts Show, some of the craziest automotive parts you have seen.

Bioceramics for Bone Replacement: The Cool Parts Show #18

Stephanie Hendrixson | Additive Manufacturing

A mandibular cage made up of two different bioresorbable ceramics points to the future of bone graft and reconstructive surgeries in this episode of The Cool Parts Show.

3D Printed Tool for CNC Machining: The Cool Parts Show #17

Peter Zelinski | Additive Manufacturing

Guhring uses additive manufacturing to make an end mill with optimized internal channels. We visit a machine shop to test the tool on this episode of The Cool Parts Show.

We Answer Your Questions About The Cool Parts Show #16

Stephanie Hendrixson | Additive Manufacturing

In this bonus episode of The Cool Parts Show, hosts Peter Zelinski and Stephanie Hendrixson answer your questions, including: What makes something a Cool Part?

How Test Swabs Became 3D Printing's Production Win: The Cool Parts Show #15

Stephanie Hendrixson | Additive Manufacturing

Nasopharyngeal swabs for COVID-19 testing are one of the best production cases for 3D printing we've seen, pandemic or otherwise. Why AM is winning on speed, functionality and collaboration.

Drone Engine Replaces 13 Parts With 1: The Cool Parts Show #14

Peter Zelinski | Additive Manufacturing

Cobra Aero discovered an opportunity for redesign it might never have found without the COVID-19 interruption providing time for product development via 3D printing. The Cool Parts Show explores how additive manufacturing is advancing during the coronavirus crisis.