This week on Pathfinder, we explore the future of 3D metal printing and manufacturing with Erik Palitsch and TJ Ronacher, co-founders of Freeform, a pioneering startup aiming to redefine industrial-scale additive manufacturing. Both SpaceX alumni, Erik and TJ share their journeys from leading projects on the Merlin and Raptor engines to co-founding Freeform, where they’re using high-power lasers and real-time process control to create a new era of rapid, scalable 3D printing.

We dive into how Freeform’s approach is addressing longstanding challenges in the additive industry, from quality control to production speed. Erik and TJ outline their vision for Freeform as a “manufacturing as a service” model, where clients can access high-quality printed parts without the steep learning curve and costs of traditional additive systems. We also discuss:

The engineering challenges they tackled at SpaceX and how that shaped Freeform’s technology and business model
Freeform’s technology, including their real-time closed-loop process that enables unprecedented print speeds and precision
Their vision for the “factory of the future,” where autonomous 3D printing facilities operate globally
The role of 3D printing in off-planet manufacturing and its impact on space exploration

And much more…

• Chapters •

00:00 - Intro

00:35 - TJ's background

02:15 - Erik's time at SpaceX before Freeform

07:25 - How has materials in 3D printing changed in the past 10 years?

12:27 - Manufacturing as a service and the tech at Freeform

18:16 - 3D printing vs traditionally manufactured parts

23:11 - What is the tech that Freeform is building?

32:45 - True factory scale 3D printing

37:10 - Traction beyond space

38:06 - What Freeform is printing today

38:41 - Revenue and customers

41:53 - Manufacturing capability today and in the future

43:51 - Advice for investors looking to invest in 3D printing

49:18 - Future of 3D printing

54:24 - What will off-planet 3D printing look like?

57:08 - Favorite stories from SpaceX days

60:47 - Milestones to look out for

• Show notes •

Freeform’s website — https://freeform.co/

Freeform’s socials —https://x.com/freeform_future

Mo's socials — https://twitter.com/itsmoislam

Payload’s socials — https://twitter.com/payloadspace / https://www.linkedin.com/company/payloadspace

Pathfinder archive — Watch: https://www.youtube.com/@payloadspace

Pathfinder archive — Listen: https://pod.payloadspace.com/episodes

• About us •

Pathfinder is brought to you by Payload, a modern space media brand built from the ground up for a new age of space exploration and commercialization. We deliver need-to-know news and insights daily to 19,000+ commercial, civil, and military space leaders. Payload is read by decision-makers at every leading new space company, along with c-suite leaders at all of the aerospace & defense primes. We’re also read on Capitol Hill, in the Pentagon, and at space agencies around the world.

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The Future of Manufacturing, with Erik Palitsch & TJ Ronacher (Co-Founders of Freeform)

Valley of Depth