Additive Snack

In this episode of the Additive Snack Podcast, host Fabian Alefeld welcomes back Paul Gradl, Principal Engineer at NASA, for a deep dive into the latest advances and challenges in additive manufacturing. Paul shares how NASA has expanded the range of available materials, pioneering alloys like GR COP and GRX 810 for extreme environments, and how these innovations are now being used in industries beyond aerospace. 

The conversation covers the rapid acceleration of material development through advanced modeling and early AI adoption, the technical hurdles of scaling up to larger parts, and the realities of additive manufacturing in space—from lunar construction to the potential of asteroid mining. Paul also discusses the importance of learning from failures, NASA’s commitment to public data sharing, and his passion for mentorship and STEM education, both at work and at home. Whether you’re an industry veteran or new to additive, this episode offers valuable insights and inspiration. 

Sign up for the NASA Metal AM Master Class today: Metal AM Master Class with NASA | EOS Store - US 

  • 2:00 - The Evolution of Additive Materials 
    NASA is expanding material options and redefining what’s possible with additive. 
  • 7:45 - Material Highlights & Cross-Industry Applications 
    Paul discusses GR COP, GRX 810, and their applications beyond aerospace. 
  • 13:45 - AI, Machine Learning & Accelerating Alloy Development 
    AI and modeling are accelerating how new alloys are developed. 
  • 17:50 - Scaling Up: Big Parts & NASA’s Role 
    NASA is driving the shift toward larger, room-sized additive parts. 
  • 23:45 - How Much of a Rocket is Additive? 
    Additive plays a growing—but complementary—role in rocket manufacturing. 
  • 26:30 - Additive in Satellites, Space, and In-Space Manufacturing 
    Additive is key to building satellites, landers, and lunar systems. 
  • 32:00 - Lunar Regolith, Moon Dust, and Asteroid Mining 
    NASA explores using Moon dust and asteroids for future construction. 
  • 36:50 - Learning from Failure: Engine Test Stand Story 
    A test stand failure highlights the importance of understanding the process. 
  • 43:45 –Metal AM Master Class Announcement 
    Details on Paul and Omar’s upcoming metal AM master class. 
  • 46:30 - Mentorship, STEM, and 3D Printing at Home 
    Paul shares how he supports STEM education at NASA and at home. 
 
 

Creators and Guests

Host
Fabian Alefeld

What is Additive Snack?

Join host Fabian Alefeld and a range of guests as they discuss all things additive manufacturing (AM) and 3D printing news, with interviews and real-world stories to educate and entertain. Each episode, Fabian talks to AM experts, professionals in specialist fields, and 3D printing users from all walks of life to deliver a well-rounded view on the state of AM.

Cut through the confusion surrounding polymer and metal additive manufacturing solutions with our digestible, down-to-earth discussions that deliver insights into common mistakes and best practice tips so you can get a clear understanding of AM — layer for layer.

Whether you’re curious about 3D printing technology for the aerospace industry, a deep dive into post processing, or applications of injection molding — we leave no spare parts behind. We want to provide you with the additive insight needed to stay laser focused and leverage every opportunity 3D printing materials have to offer.

Join us for an Additive Snack and we’ll help you and your business achieve growth and success through the latest developments in AM.

No marketing B.S. and no product pitches. Just the education, inspiration and information you and your organization need to drive business growth, brought to you by global AM leader EOS.

Get ready to feed your AM knowledge and find your path to success!