An AM Optimistic Pessimist

“There are many great ideas on how to use AM, but just as many bad ones.”

With a background as an aerospace structural designer utilizing traditional manufacturing processes, Michael Hayes brings a unique perspective in applying additive manufacturing (AM) technologies. He witnessed the advent of additive manufacturing about 15 years into his 34-year career with Boeing. It was when he was designing large, structural components, titanium bulkheads with composite skins, and someone said, ‘Here is a stereolithography machine, now let’s print all the aircraft parts.’ It was easy to laugh with cynicism. However, what began as skepticism soon transformed into recognition of the technology's potential for safety improvements, quality enhancements, and cost reductions.

During his last ten years at Boeing, Michael assumed the role of Technical Lead Engineer for the development and application of polymer/composite AM within the company. He spearheaded strategic initiatives that translated into enterprise-wide advancements. As a Boeing subject matter expert in AM, Michael worked across several Boeing programs to transition ideas and opportunities for improvement into AM applications. The concepts were plentiful but not all great; some were mediocre at best, and others were failures.

Michael recounts a story of being in a program review with a new manager to discuss a specific application of AM technology—one that Michael didn't agree with. The manager leaned over and remarked, "I thought you were supposed to be someone who likes AM?" To which Michael responded, "Only when it makes sense."

Drawing from his extensive experience across various manufacturing technologies, not just AM, Michael emphasizes the importance of recognizing that AM is not the ultimate solution for every challenge. AM is not the ‘end-all-be-all’ of solutions, but rather AM is another tool in the manufacturing toolbox. It’s valuable when appropriately applied.

In his role with TBGA, Michael thoroughly enjoys collaborating with TBGA’s wide scope of advanced manufacturing customers to review and assess their goals. He assists in devising strategies that may or may not utilize AM. He has a tremendous amount of experience with polymer additive manufacturing because the maturity of the technologies and flexibility of the systems offer a number of great opportunities. And even though Michael will say that AM has a long way to go–he will also state that it is a great technology and has a large number of great applications. A true AM optimistic pessimist perspective.