How Protolabs turns CAD files into parts in under 24 hours

Design for manufacturing is changing faster than most robotics teams can keep up - and if you are building physical products, this conversation could save you months of rework. Marc Kermisch shares how Protolabs is using AI, simulation, and deep manufacturing expertise to turn CAD files into real parts in as little as 24 hours, while helping engineers avoid the design mistakes that quietly kill speed, quality, and scale.

Mike Oitzman and Gene Demaitre sit down with Marc, who has returned to the show since episode 138 with a new role as CTO and AI leader at Protolabs. He explains how the company’s software-driven approach links CAD models directly to manufacturing tool paths, G code, and production workflows across CNC machining, 3D printing, injection molding, and sheet metal - all built around the challenge of helping engineers get parts made faster without sacrificing precision.

You’ll discover:

- Why Protolabs treats AI as a practical manufacturing tool, not hype

- How machine learning helps catch manufacturability issues before a part is ever built

- What ProDesk does when it flags ejector locations, tight tolerances, seam issues, and other hidden design risks

- How part similarity search and simulation speed up internal decisions for engineers

- Where AI is already paying off in visual inspection, cobot programming, and print-box optimization

Marc also breaks down the real-world tradeoffs between 3D printing, CNC machining, and injection molding, including when a prototype should stay a prototype - and when it’s time to redesign for production. He gets specific about common failure points like draft angles, wall thickness, shrink, resin changes, tooling assumptions, and the gap between prototype tolerances and production reality.

If you’re dealing with robotics, hardware, manufacturing, or any physical product that must move from concept to production, this episode shows what happens when software, AI, and manufacturing expertise work together instead of in silos. It’s especially valuable for founders, roboticists, and engineers who need to make smarter decisions before the first expensive mistake happens.

Protolabs is also building for the future of compliance, supply chain resilience, and low-volume production, with a network that helps customers de-risk sourcing, reduce complexity, and stay aligned with regulated industries like defense, aerospace, and medical devices. The result is a rare inside look at how modern manufacturing is evolving - and how the next wave of physical products will get made.

Essential listening if you are building hardware, scaling production, or trying to make your robot, part, or process easier to manufacture the first time.