In this episode of the Additive Snack Podcast, host Fabian Alefeld is joined by Thomas Pomorski, Director of Additive Manufacturing at Ursa Major. Tom discusses his extensive background in additive manufacturing, including his work at Bechtel Plant Machinery and Penn United. He shares insights into Ursa Major's journey in scaling propulsion manufacturing for space and defense, emphasizing the importance of insourcing, quality systems, and the iterative approach in additive development. 

Tom delves into the challenges and solutions in scaling additive manufacturing, including complex parameter strategies, automation, and flexible manufacturing. He also highlights Ursa Major’s products, such as the Hadley and Draper engines, and the company's innovative approach to solid rocket motor manufacturing. The episode concludes with Tom's advice for companies looking to scale additive manufacturing operations and a look into the future of the industry.

01:46 Tom's Journey into Additive Manufacturing

02:04 Early Career and First Additive Roles

04:38 Joining Ursa Major and Initial Challenges

10:11 Vertical Integration and Scaling Challenges

20:14 Advanced Additive Strategies and Collaborations

26:28 Automating Build Setups with Python

26:58 Challenges in Hiring Additive Process Engineers

28:06 Building a Passionate and Skilled Team

29:30 Leveraging Local Talent and Resources

31:17 Collaborating Across the Aerospace and Defense Industry

32:50 URS's Product Portfolio and Additive Manufacturing

35:34 Flexible Manufacturing for Solid Rocket Motors

39:07 Future Developments in Additive Manufacturing

41:35 The Importance of Material Development

46:29 Scaling Operations and Advice for Newcomers