Every manufacturing shop is different, but this one has a machine named Frodo (and also Sauron). This shop also celebrates successes not just with high fives, but with ice cream. We sat down with Jordan Abrams, Sales Ops Program Manager at A3D to get the behind-the-scenes look at what it’s really like on the A3D Manufacturing floor.
The Shop “Vibe”
Q: What kind of machines do you have in the shop?
A: An assortment of different 3D printers ranging from Formlabs to Markforged to HP’s 5200 and 5400 series.
Q: What song is currently on repeat in the post-processing room?
A: It’s different every day. We all take turns playing music around the shop, from reggaeton to heavy metal to house and top 100’s.
Q: What’s the most satisfying moment in the shop?
A: Most satisfying moment in the shop is manually blasting parts.
Q: What’s one myth customers believe about 3D printing that you love debunking?
A: Showing them how many different types of 3D printing tech is out there, and it’s wide variety of applications.
Q: If you had to replace one manual post-processing step with a robot tomorrow, which would it be?
A: Unpacking builds. Hands down.
Q: What does the shop smell like on a good day vs. a bad day?
A: On a good day, the shop doesn’t smell like anything. On a bad day, the shop smells like almonds and Cerakote. Most days are good days, thankfully.
Q: How many technicians are working at the shop/ running the equipment and post processing?
A: We have roughly 3 people working the machines consistently. But we all help to keep the shop moving.
Q: What’s a typical day-in-the-life like working at A3D manufacturing?
A: Full plate, everyday. The teamwork is what makes a major difference. We aren’t afraid to ask for help when we need it.
Q: Where’d the unique names for the printers and tech come from?
A: Taylor Moore! He always finds a way to come up with the perfect name for the printers or new tech around the shop.
Q: What’s the wildest “midnight mishap” you’ve had during a lights-out print run? Or another relevant mishap that maybe you turned into a learning experience?
A: We had a power outage during a big storm overnight that caused all the machines to shut down. But we recovered in the morning almost instantly. We took that as an opportunity to examine our power usage and make it more effective.
Q: Do you have a running count ticker of how many parts printed in the shop or any fun motivational metrics your team is continually looking at?
A: Yes, we track tons of different metrics to be on top of our productivity. Parts printed, Parts Shipped on time. Material usage/popularity.
Q: How do you celebrate a flawless first-article inspection or job done well? Is there a secret shop high-five ritual or victory playlist?
A: Management usually buys us lunch or ice cream. But we rarely have time to slow down during our workdays. Often Management shows appreciation for the shops’ efforts by going all out for company offsite events.
Q: What’s one non-manufacturing skill a technician brought to the shop that totally saved the day (e.g., MacGyver-ing a jammed build plate)?
A: One of our old technicians was a former blacksmith, and he would be able to muscle his way into success often.
Q: What’s the funnest/coolest machine to use? Why?
A: I really enjoy the manual blasting machine. It’s where you get to really see a parts geometry for the first time. You really start to wonder what this could be used for or where a part fits into an assembly.
Q: Ever had a printer “ghost” a part that looked perfect in software but turned into a surreal sculpture — share your funniest fail-and-fix tale?
A: Once, we had a print that was a little too densely packed, so all the smaller parts fused together like monkeys in a barrel. We just reprinted the parts later in the day.
Q: What’s the most complicated “multi-method” job and how many machines and steps are involved?
A: That’s under an NDA, but I can say it has 10 steps along its process, stopping at 5 different machines.
Q: What’s the best “aha!” moment a new technician has had while running post-processing, like dyeing or vapor smoothing a tricky batch?
A: Finding the right tool to clear out powder from parts with complicated internal channels.
Q: If A3D’s shop floor was a reality TV show, what would the episode titles be for your most epic customer rush jobs?
A: When the Build Plate Hits the Fan, Powered by Caffeine & Chaos, Chip Happens
Q: How has hosting events like the Women in 3D Printing Phoenix meetup changed the shop’s energy — any standout guest stories?
A: It’s life changing to get to connect within this community or share the possibilities for women entering the STEM fields. Every year we host this event; the community grows stronger.
Q: What’s one piece of advice from a veteran tech to a rookie on surviving a 24-hour turnaround without losing your cool?
A: Ask for help. Preferably long before panic sets in. We operate best when departments are communicating with each other and lending a hand.
Q: How many machines have googly eyes on them. Be honest.
A: None sadly. But now there will be. The shop vacs will be first.
AI, LLMs, and The Future of A3D Manufacturing
Q: In the future with more general-purpose robotics, how do you imagine A3D’s shop evolving?
A: A lean manufacturing process that combines automation tools and human ingenuity to achieve peak production.
Q: How are LLMs sneaking into your quoting process, like auto-generating DFAM tips for uploaded files — any hilariously wrong suggestions yet?
A: We are very vigilant about coaching our LLM’s in my personal experience nothing too funny has happened yet.
Q: If AI could “remix” a classic shop tool (e.g., a smart caliper that trash-talks bad tolerances), what invention would your team pitch?
A: If we could redesign our picks in the office to operate like precision surgical equipment for those hard-to-reach supports. Flexible but with a strong grip.
Q: Is the team using ai workflows to scan workflow logs to data mine productivity or look for opportunities? If not, what kinds of things might that be useful for? Have you heard of other shops doing so?
A: We are using it to run P.O reviews to speed up the sales process.
Q: What are the future investments for automation?
A: Rumors are around expanding our print compacity and automating our unpacking process.
Q: How is the shop leveraging LLMs and AI in workflows and automation?
A: It’s more incorporated on the quality and sales side of the business. We prefer to take a hands-on, people forward, approach that coexists with machine automation.
Q: Peering five years ahead: Will A3D’s HQ look like in the future?
A: Honestly at our current growth rate, in 5 years, we are going to need a new facility again to accommodate the new machinery, larger output and more post processing services we will offer.
Q: What didn’t we ask that people should know about A3D Manufacturing?
A: A3D and our network of strategic partnerships allow us to become a one stop shop for all your manufacturing needs, held to a high standard by our quality control department. Our office makes customer-facing communication quick, easy, and efficient.
