Key Takeaways
- Vic Fryzel joins Velo3D as Executive Vice President, Technology, bringing >20 years of hardware‑software systems experience from Carbon, Meta, Lyft, and Google.
- Robert Purnell becomes Senior Director, Operations, adding aerospace‑and‑semiconductor manufacturing expertise from Boeing, FormFactor, SpaceX‑Starlink, and the U.S. Marine Corps.
- Both executives will steer the technology roadmap and production systems at Forge 1, Velo3D’s 150,000 sq ft Livermore campus.
- Their appointments reinforce Velo3D’s Rapid Production Solutions (RPS), enabling customers to tap high‑mix, low‑volume AM capacity without building in‑house printer farms.
New Technology Leadership at Velo3D
Vic Fryzel – Executive Vice President, Technology
Vic Fryzel arrives with a portfolio that spans more than two decades of scaling complex hardware and software ecosystems. His recent tenure includes senior roles at:
| Company | Role | Notable Contributions |
|---|---|---|
| Carbon | Senior Director, Engineering | Led the development of the first commercially viable DLS (Digital Light Synthesis) platform, increasing build speed by 3‑5×. |
| Meta | Head of AR/VR Hardware | Oversaw the integration of custom ASICs that reduced latency to < 5 ms. |
| Lyft | Director of Autonomous Systems | Implemented a data pipeline processing > 2 PB/year of sensor data. |
| Senior Staff Engineer | Contributed to the Tensor Processing Unit (TPU) hardware stack, boosting AI inference throughput by 8×. |
At Velo3D, Fryzel will own the technology roadmap across six pillars:
- Hardware architecture – next‑gen laser sintering heads (up to 2 kW power).
- Software stack – VeloWorks 5.0 with real‑time build monitoring.
- Materials science – expansion to 12 alloy grades, including Inconel 718 and Ti‑6Al‑4V.
- Automation – robotic material handling capable of 30 parts/hr.
- Process engineering – closed‑loop thermal control ± 2 °C.
- Data & AI – predictive defect detection with > 95 % accuracy.
Robert Purnell – Senior Director, Operations
Robert Purnell’s résumé blends high‑volume aerospace manufacturing with fast‑pace semiconductor production. Prior positions include:
| Company | Position | Core Achievements |
|---|---|---|
| Boeing Co. | Manufacturing Engineering Lead | Directed a 400‑person line that delivered 1,200 airframe sections per year. |
| FormFactor Inc. | Operations Manager | Scaled wafer‑probe stations from 2 to 12 units, cutting cycle time by 40 %. |
| SpaceX – Starlink | Production Systems Supervisor | Managed the assembly of 5,000+ satellite units, maintaining < 0.5 % scrap rate. |
| U.S. Marine Corps | Logistics Officer | Oversaw supply chain for 12,000 + personnel, achieving 99.8 % on‑time delivery. |
At the Forge 1 campus—Velo3D’s flagship 150k sq ft facility—Purnell will supervise the teams responsible for:
- Safety compliance (ISO 45001 certification target Q4 2026).
- Quality assurance (goal: < 30 ppm defects, aligned with AS9100D).
- Delivery performance (on‑time build completion ≥ 95 % for RPS contracts).
How Their Roles Strengthen Rapid Production Solutions
Velo3D’s Rapid Production Solutions (RPS) platform offers “printer‑as‑a‑service” for aerospace, defense, and high‑performance automotive customers. By centralizing:
- Machine uptime (target 98 % across 12 production printers).
- Material inventory (stock of 12 alloy powders, each > 1 ton).
- Post‑process capacity (heat‑treat and CNC finishing lines handling 500 parts/day).
the RPS model eliminates the capital expense of a dedicated AM line, which typically exceeds $3 M per printer plus $1.5 M in ancillary equipment.
Comparison: In‑House AM vs. Velo3D RPS (2026 data)
| Metric | In‑House AM (single printer) | Velo3D RPS (multi‑printer fleet) |
|---|---|---|
| Capital cost | $3–5 M | $0 (pay‑per‑part) |
| Build lead time | 4–6 weeks (setup + qualification) | 1–2 weeks (queue‑based) |
| Part quality (defect ppm) | 80–120 ppm | 20–30 ppm |
| Material waste | 12 % (support structures) | 6 % (optimized nesting) |
| Scalability | Linear (add printer) | Exponential (shared pool) |
Bottom Line
Velo3D’s appointment of Vic Fryzel and Robert Purnell injects deep, cross‑industry expertise into both the technology and operations arms of its business. Fryzel’s track record of accelerating hardware‑software convergence and Purnell’s proven ability to run high‑mix, high‑precision production lines position Forge 1 to deliver on the ambitious goals of the Rapid Production Solutions service. For manufacturers seeking to leverage metal additive manufacturing without the overhead of a dedicated printer fleet, Velo3D’s expanded leadership team signals a stronger, more reliable partner ready to meet demanding aerospace and defense schedules.
For additional details, visit the official Velo3D site: https://www.velo3d.com/.