A decade ago, engineers shifted their approach from simply adding additive manufacturing (AM) to existing processes to embracing design-for-additive manufacturing (DFAM). The work done in 2014-2015 to create more functional parts has now evolved into the long-term production of qualified metal-AM components for the aerospace, defense, energy, power generation, and other niche industrial applications. “Metal additive manufacturing changed the way engineers think,” says James Hockey, the director of business development, Incodema3D, Freeville, New York, near Ithaca. Incodema3D – an acronym for invent, concept, design, and manufacture – embodies a shift in metal AM thinking. Evolving from a traditional job shop, it now specializes in production parts using laser powder bed fusion. The company now operates 35 EOS North America systems, including four EOS M 400-4 (with four lasers and quadrant overlap) and four EOS M 300-4 (with full field access for using all four lasers in concert). As Incodema3D continues to scale its AM production, the need for efficient post-processing and streamlined workflows has become increasingly critical. With a growing demand for high-quality, production-grade metal-AM parts in industries like aerospace and defense, the company recognized that automation was key to maintaining precision, reducing lead times, and optimizing throughput. Kevin Engel, director of additive operations at Incodema3D, notes that the company used the past two IMTS shows to acquire subtractive technologies to support its additive growth – a shift from a conventional approach. “We added a Behringer band saw and two Mazak i-700 Variaxis machining centers with a Palletech High Rise automated pallet handling system,” says Engel. “With 24 pallets, we increased post processing efficiency and support the low-volume, high-mix production typical of aerospace and defense.” Incodema3D acquired this Behringer saw at IMTS 2024. Shown (L-R) are Eric Olmeda, Behringer sales manager, Joe Suydam, national sales manager and James Hockey, Incodema3D director of business development.The Variaxis i-700 five-axis vertical machining center performs complex, curved surface machining on large workpieces in a single setup with a table size of 27.56- × 19.69-inches. Its 120-tool storage capacity enhances flexibility and extends run-time with duplicate tools. “We attend IMTS because we can make direct comparisons between different machine providers in one place,” says Engel. “We can accomplish this in a short time period because exhibitors bring their entire teams, enabling us to assess machine capabilities and service.” “The Mazak manufacturing cell enables a level of unattended operation that reflects the level of automation in our additive manufacturing equipment,” adds Matt Lewis, vice president of programs at Incodema3D. “We are always looking for new ways to extend the impact of the skilled machinists on our team. Our drive to increase unattended operations allows the team to focus on new product introduction with the confidence that existing production will continue to meet customer needs.” Lewis notes that the precision and repeatability of the Mazak i700 have rapidly reduced the amount of time it takes to develop new part numbers. “We are able to adjust for part-to-part variation present in additive parts in real-time to protect critical features without needing part specific set-up times,” he says. Incodema3D has been a cutting-edge implementer of laser powder bed fusion technology. “As we take on more difficult customer programs, we are moving to the forefront of post-processing equipment technology,” says Lewis. “At IMTS 2026, we will continue to look into machines with higher throughput on both AM and postprocessing, and automation to manage our delivery times.” Your Roadmap to IMTS 2026 Check out the IMTS 2026 exhibitors and floor plan. Make plans now to attend North America’s largest manufacturing solution showcase. IMTS 2026 will take place Sept. 14-19, 2026, at McCormick Place in Chicago. Sign up to get the latest information about IMTS 2026 at IMTS.com/SaveTheDate.
Incodema3D added two Mazak i-700s and a 24-pallet Palletech system—sourced at IMTS—to automate post-processing, boost efficiency, and scale high-mix, low-volume part production.
Subscribe to Newsletters
Get the latest news from IMTS delivered to your inbox.