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. 

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• 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.