Our Solutionology podcast shares behind-the-scenes stories of projects and problem-solving using a digital mindset. In Episode #25, Carl Douglass, DI Lab CEO, and Brian Douglass, DI Labs COO, have an in-depth discussion about quality with Hannah Kinder, DI Labs Production Manager.

Quality can be a touchy subject in additive manufacturing because it often seems ambiguous and expectations can be wildly different between each client and project. Brian states that quality, which is considered a deliverable, and a digital mindset, which is a state of constant transition, can feel like oil & water. That’s because when people think of quality, they think of standardization and repeatability - not constant change.

As the industry continues to evolve and mature, having a digital mindset is critical to our success, especially when it comes to quality. DI Labs is in a constant state of transition to new levels of performance, capabilities and standards of quality. As Hannah said in the wrap-up, change is inevitable especially if you want to be better. And we always do.

Listen to the full episode to learn more.

Chapters & Episode Topics:
00:00 Intro
01:02 Structure of quality
01:27 Digital mindset and quality - oil and water
03:15 Quality is a tradeoff
04:06 Definitions of quality
05:50 Culture supports quality
07:51 Our ISO9001 onboarding process
11:53 Understanding client expectations
15:45 How quality drives scrap rates
18:59 Scrap from 10-25%
19:11 Current improvements

More Solutionology Stories Podcast Episodes: https://dilabs.cc/podcast/

What is a digital mindset, and how does it add value to the product development, design, management & manufacturing process?

In Episode #24 of the Solutionology Podcast Carl Douglass, P.E. and Brian Douglass from DI Labs dig into this topic.

Brian starts by providing a simple definition of a digital mindset from the DI Labs perspective. "A digital mindset is a way for us to stay flexible throughout a process or project... so that we're not locked into a preconceived bias... it's the ability to create rapid changes and store them in a quick and lightweight format like digital..."

Carl then quotes an article from the Harvard Business Review by Tsedal Neeley and Paul Leonardi called, "*Developing a Digital Mindset." Under the section "Change as a Constant" he reads:

According to change management theory, organizations move from a current state to a transitional state and then on to a future state... In a digitally driven world, however, there is no endpoint to the transitional phase.

This excerpt resonated with Brian and Carl due to the never-ending state of transition, which is a mindset they embrace. Listen to the full episode to hear more.

**Find the full article here.

At DI Labs, we've been applying a digital mindset for a long time and now help clients build it into their programs and products, leading us to what's next! Stay tuned to learn more about the custom-designed Solutionology Sessions we'll be offering to companies interested in mobilizing their teams with a digital mindset.

More about DI Labs: dilabs.cc
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What does it mean to have a digital mindset and how does it open up possibilities in product development and manufacturing? On this episode of the Solutionology Podcast, Carl and Brian share DI Lab’s journey in creating a consumer product line that has grown exponentially by leveraging the power of a digital mindset and manufacturing process. It allowed us to approach the market without the constraints of traditional manufacturing, accelerate our product launch, and give us a competitive edge through customization.

We started by solving a very specific problem which quickly revealed unexpected market demand and an opportunity to create a wide spectrum of products and variations. Our technology tools include the HP Multi Jet Fusion for printing and the AMT PostPro for finishing.

00:00 Intro
00:34 Welcome - we’re in a different space
01:13 Product owners and manufacturers
01:51 Product development & testing
02:36 Solving a problem
05:21 Mass customization workflow
07:17 Segmenting the market for variations
08:57 Maximizing value with a digital mindset
09:56 The tools needed
10:57 What we’ve learned

Recently, Carl and Brian Douglass were guest experts on a Webinar hosted by MasterGraphics and Mindfire. We are posting this as an episode of the Solutionology Podcast with their permission. Access the original posting here.

Could you elevate your Approach with a Solid Plan from the Experts?

Challenge the status quo by asking yourself: Is your current additive manufacturing plan truly optimized, and how can you elevate it to new heights of success?

Prepare for enlightening insights as our experts share their valuable knowledge. You'll hear from 4 expert panelists:

• Carl Douglass, CEO, DI Labs
• Brian Douglass, COO, DI Labs
• David Rosendahl, President & Co-Founder, MindFire Inc
• Kevin Carr, President, MasterGraphics

In this session, our panelists will analyze and exchange insights on:

• How embracing Additive Manufacturing can reshape your product development approach, fostering agility and sparking creative ingenuity.
• Why having a structured process for product development through Additive Manufacturing is not just advantageous, but essential.
• How aligning your additive manufacturing strategies with your business goals can drive growth, boost efficiency, and amplify your competitive edge.
• Whether you're a business owner, product manager, or industry professional, this webinar offers valuable insights and practical strategies for anyone seeking to enhance their additive manufacturing prowess.

In this mini-episode of the Solutionology Podcast, we’re addressing some of the most common questions we get about volume production using additive manufacturing. In fact, these questions were the driving force behind a technical presentation that Carl Douglass, DI Labs CEO, created and will be delivering at the Medical Device and Manufacturing tradeshow in Minneapolis. We’re just getting warmed up and hope to see you there!

Common questions about volume production with additive manufacturing:

• What types of applications and projects are the right fit?
• What reasons should drive the decision to use additive?
• What reasons should drive the decision NOT to use additive?
• What does the production part approval (PPAP) process look like?

Takeaways from Carl’s presentation:

• To successfully leverage additive for production, build it in early
• High-tolerance parts are possible
• Additive shouldn’t be considered the end-all-be-all
• Additive can be a superpower if used in the right applications

Related Content:

• MD&M technical presentation details
• Article in "Plastics Today" about the presentation

Chapters & Topics:
00:00 Intro
00:15 Welcome
00:40 MD&M presentation takeaways
02:27 Go & yield applications for additive
04:51 Organizational limitations
05:34 Need a champion and stakeholders
08:28 Keys for successful production
09:27 Developing a production part approval process
11:37 Validating biocompatibility for medical device
13:35 Biggest shortcomings in preparing for additive
14:06 See you at MD&M

More about DI Labs:
https://dilabs.cc/

We’re back with a favorite client and good friend, Mike Van Staagen, owner of Van Staagen Design and VP of Advanced Design and Development for Cirrus Aircraft.

In this episode, Mike talks about working with a company to design the internal body of a very specialized camera about the size of a soda can. He explains how leveraging the DI Labs Multi-Jet Fusion (MJF) capabilities for final production allowed him to drive complexity into his final design. His solution included a single printed part, which he describes as “impossible,” that held over 20 components together and went through multiple iterations to add new features such as snaps, wire runs, and clips. Mike calls MJF technology "a solution that can grow with you."

More about DI Labs.
Watch all of our Solutionology Podcast Episodes on YouTube.

Related Content:

• Ep #18 | The Impact of Rapid Modeling at Full Scale: Cirrus Fuselage
• Ep #19 | Insights from a 30-Year Career in Product Design w/ Mike Van Staagen

In this special episode, we got 30 years of wisdom from renowned product and aviation designer, Mike Van Staagen. Mike is extremely passion about sharing what he's learned on his professional journey which started with architecture and led to his current position as VP of Advanced Design and Development for Cirrus Aircraft.

Among Mike's many career achievements, he helped to envision, design and lead teams for the best-selling Cirrus SR20/22 aircraft. He was also the creator and driving force behind the Cirrus SF50 Vision personal jet.

Here's a snapshot of the insightful and powerful points Mike makes in this episode. If you're looking for inspiration, take a listen!

Episode Topics:
00:00 Intro
01:41 Thinking like an architect changes your perspective
06:25 If a picture is worth 1,000 words, then models are worth 1,000 pictures
07:33 Making bold moves can create bold results
18:17 A design is never, ever finished
20:11 Accidental discovery is a superpower, so create opportunities for it to happen
25:56 Models and prototypes are the best possible ambassador for your design
32:14 Polygon modelers are easy to manipulate and like having digital clay

Watch all of our Solutionology Podcast Episodes on YouTube:
• Solutionology Podcast

More about DI Labs:
https://dilabs.cc/

Don’t miss this conversation with a favorite client and good friend, Mike Van Staagen. Mike is a renowned designer of aircraft, mobility solutions, products of all sorts, and a manufacturing engineer with an award-winning 30-year career. He currently serves as the VP of Advanced Design and Development for Cirrus Aircraft while also operating his own design firm. Mike's many accolades include helping to envision, design and lead teams for the best-selling Cirrus SR20/22 aircraft. He was also the creator and driving force behind the Cirrus SF50 Vision personal jet.

In this episode, Mike explains the daunting challenge he brought to DI Labs during the design phase of a new Cirrus aircraft project. Our solution, which was delivered to Cirrus in just 30 days, was a full-scale fuselage prototype created using additive manufacturing. We printed over 130 thin-walled panels and developed a proprietary system of mechanical joints and assembly to build a 10' x 4.5' model that became the ambassador of Mike’s new design concept.

Dimensional accuracy was critical in this project which is why it is a perfect example of Mike's theory that 1/8 of an inch can make all the difference.

00:00
01:07 Welcome and introduction
03:32 Accomplishments at Cirrus
04:30 Ideas behind the Cirrus SR20 & SR22
07:14 Creating the best passenger experience
08:07 Hand constructed full-scale fuselage of the vision jet
11:12 The ⅛’s of an inch difference
12:11 3D printed full-scale fuselage shows ⅛’s of an inch
14:22 An accomplishment

See this project profile on our website: https://dilabs.cc/portfolio-item/full...

Watch all the episodes on YouTube: Solutionology Podcast

Learn more about DI Labs: https://dilabs.cc/