Freeform, a startup founded by former SpaceX engineers, has raised $14 million in funding from industry giants Nvidia and Boeing to transform the landscape of metal 3D printing. While 3D printing with metal is not new, the challenges of complexity, cost, and precision have hindered its widespread adoption. Freeform aims to address these issues by introducing a groundbreaking additive printing process that leverages artificial intelligence.
Co-founders Erik Palitsch (CEO) and TJ Ronacher (President) bring their extensive experience from SpaceX, where they were instrumental in developing the Merlin engines. They witnessed the potential of metal 3D printing firsthand but also recognized its limitations. “Metal printing can revolutionize any industry that manufactures metal parts,” Palitsch explained. “Yet, adoption has been slow due to inconsistent quality, slow printing speeds, and exorbitant costs.”
To overcome these hurdles, Palitsch and Ronacher partnered with Tasso Lappas, former CTO of Velo3D, to create Freeform. Their innovative approach shifts the focus from selling individual printers to providing a comprehensive printing service.
Traditional metal printing relies on CNC machines, which necessitate expert knowledge from users. In contrast, Freeform’s custom-built machines employ a closed-loop system that continuously monitors the printing process at a microsecond scale, adjusting parameters in real-time to ensure precision.
Key to their success is a sophisticated AI-driven feedback loop that utilizes high-speed computer vision. This allows for immediate adjustments during the printing process, mitigating quality issues and enabling the production of complex geometries efficiently. “We had to build an entire tech stack from scratch, utilizing advancements that have only recently become available,” Palitsch said.
The company’s unique model allows them to collect extensive data on the printing process, creating what they claim is the largest metal additive dataset in the world. This proprietary data fuels their machine-learning models, enabling precise control over the printing process.
Boeing and Nvidia’s investments not only provide capital but also critical resources: Nvidia offers access to cutting-edge hardware like the H100, while Boeing facilitates the supplier qualification process, likely leading to significant purchasing opportunities.
Freeform serves a diverse array of sectors, including aerospace, automotive, industrial, and energy. Their innovative approach has attracted attention from clients needing everything from rocket engine components to Formula 1 exhaust parts.
With plans to scale operations, develop faster printers, and expand their team from six to 55, Freeform is on a mission to redefine metal 3D printing. “It’s been a slow journey, but we’ve built the fastest laser melting platform on the planet,” Palitsch noted. “We’re proving that what others thought was impossible can be achieved.”
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