Strategic Partners Deep Dive

Mr. David Edelen has provided Additive Manufacturing (AM) subject matter expertise to the Department of War (DoW) and the private sector for over ten years. His experience includes producing and maintaining a three-dimensional (3D) printer product line, business development, and developing new AM technologies, materials, and applications. In 2017, Mr. Edelen created an open-source, closed-loop 3D printer motion control system1 2 3 and conducted research at the University of Maryland (UMD), co-authoring an article published in the Journal of Sandwich Structures and Materials titled “Predicting failure modes of 3D printed multi-material polymer sandwich structures from process parameters,” 4 which has been cited by researchers globally over 25 times.

Mr. Edelen currently supports Department of Navy (DON) Naval Air Warfare Center Aircraft Division (NAWCAD) customers with AM expertise and sustainment of design and manufacturing of parts using deployed AM systems. He is also involved in a Collaborative Research and Development Agreement (CRADA) with the Department of Air Force (DAF), supporting their AM development initiatives. He has helped integrate a Directed Energy Deposition (DED) print head into a Haas VF1 for hybrid additive and subtractive manufacturing capabilities and developed a minimal viable product for 3D printing ammonium perchlorate solid composite rocket motors. Commercial customers in the autonomy market are using Mr. Edelen’s knowledge and KAIROS Additive’s capabilities to produce functional components for their systems. He has overseen the development of flaw detection hardware and software for identifying flaws, and automated production in concrete 3D printed structures for commercial and residential building applications.

Mr. Edelen continues work in advancing AM technologies through patented flaw detection systems 5 6. This technology is intended to reduce the risk of part failure, supporting strength and reliability in functional or structural components such as flight certified or load bearing parts. Additionally, he developed patent-pending 3D modeling software7 designed to expand manufacturing capability in the field with AM systems. Mr. Edelen is also working on advanced materials, including those filled with carbon/glass fiber or nanomaterials, and aims to improve process control by enhancing closed-loop sensory feedback in critical machine processes.

1.  Aaron Louis Technology to launch first open-source 3D printer with closed loop motor on Kickstarter. (2017, May 3). Retrieved from http://www.3ders.org/articles/20170503-aaron-louis-technology-to-launch-first-open-source-3d-printer-with-closed-loop-motor-on-kickstarter.html
2.  Saunders, S. (2017, May 12). Dark Chip Industrial 3D Printer Series Features Closed Loop Control and Open Source Software – 3DPrint.com: The Voice of 3D Printing / Additive Manufacturing. Retrieved from https://3dprint.com/174136/kickstarter-campaign-closed-loop
3.  Ahmed, R. (2017, May 16). Aaron Louis Technologies Kickstarter Develops New Dark Chip 3D Printers. Retrieved from https://3dprinting.com/news/aaron-louis-technologies-kickstarter-develops-new-dark-chip-3d-printers/
4.  Edelen DL, Bruck HA. Predicting failure modes of 3D-printed multi-material polymer sandwich structures from process parameters. Journal of Sandwich Structures & Materials. 2022;24(2):1049-1075. doi:10.1177/10996362211020445
5.  Edelen, D. L. (US12023869B2). Detecting irregularities in layers of 3-d printed objects and assessing integrity and quality of object to manage risk.
6.  Edelen, D. L. (US20240308144A1). Identifying irregularities in additively manufactured objects to evaluate structural integrity and quality
7.  Edelen, D. L. (US20230021899A1). Dynamically creating three-dimensional object files for components needing to be replaced at point of need.