Thomas Spears, Ph.D. Physics
Director of Advanced Additive Manufacturing Technologies (Open Additive) at Open Additive an ARCTOS group- Claim this Profile
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Bio
Michael Lexa
In 2016 and 2017 I worked with Tom on two internal GE projects to create a next generation suite of analytics to monitor the meltpool during DMLM manufacturing. The goal was to detect abnormalities manifested in the meltpool's characteristics during the build process so as to avoid the production of defective parts and to increase efficiency. At the time I was working at GE Global Research and Tom was the technical and project lead at GE Aviation and then GE Additive. Tom was a pleasure to work with. Communication was easy and he was very knowledgable about the additive materials and equipment. Tom quickly understood the concepts behind the algorithms within the analytics and successfully lead the first project, focused on the feasibility of the analytics, to the second project that was aimed at transforming the technology into a product. I would definitely work with Tom again.
John Kleek, Sr
Before retiring in Jan 2018 from AFRL Materials and Manufacturing Directorate, I worked with Tom at GE on a project that developed sensing technologies and data analytics to better detect defects during powder bed laser fusion processes of nickel alloys and how to overcome the defects. Tom had the expertise and capability to successfully carry out the project both experimentally and programmatically. The project was a huge success thanks to Tom's diligent work and analytics background.
Michael Lexa
In 2016 and 2017 I worked with Tom on two internal GE projects to create a next generation suite of analytics to monitor the meltpool during DMLM manufacturing. The goal was to detect abnormalities manifested in the meltpool's characteristics during the build process so as to avoid the production of defective parts and to increase efficiency. At the time I was working at GE Global Research and Tom was the technical and project lead at GE Aviation and then GE Additive. Tom was a pleasure to work with. Communication was easy and he was very knowledgable about the additive materials and equipment. Tom quickly understood the concepts behind the algorithms within the analytics and successfully lead the first project, focused on the feasibility of the analytics, to the second project that was aimed at transforming the technology into a product. I would definitely work with Tom again.
John Kleek, Sr
Before retiring in Jan 2018 from AFRL Materials and Manufacturing Directorate, I worked with Tom at GE on a project that developed sensing technologies and data analytics to better detect defects during powder bed laser fusion processes of nickel alloys and how to overcome the defects. Tom had the expertise and capability to successfully carry out the project both experimentally and programmatically. The project was a huge success thanks to Tom's diligent work and analytics background.
Michael Lexa
In 2016 and 2017 I worked with Tom on two internal GE projects to create a next generation suite of analytics to monitor the meltpool during DMLM manufacturing. The goal was to detect abnormalities manifested in the meltpool's characteristics during the build process so as to avoid the production of defective parts and to increase efficiency. At the time I was working at GE Global Research and Tom was the technical and project lead at GE Aviation and then GE Additive. Tom was a pleasure to work with. Communication was easy and he was very knowledgable about the additive materials and equipment. Tom quickly understood the concepts behind the algorithms within the analytics and successfully lead the first project, focused on the feasibility of the analytics, to the second project that was aimed at transforming the technology into a product. I would definitely work with Tom again.
John Kleek, Sr
Before retiring in Jan 2018 from AFRL Materials and Manufacturing Directorate, I worked with Tom at GE on a project that developed sensing technologies and data analytics to better detect defects during powder bed laser fusion processes of nickel alloys and how to overcome the defects. Tom had the expertise and capability to successfully carry out the project both experimentally and programmatically. The project was a huge success thanks to Tom's diligent work and analytics background.
Michael Lexa
In 2016 and 2017 I worked with Tom on two internal GE projects to create a next generation suite of analytics to monitor the meltpool during DMLM manufacturing. The goal was to detect abnormalities manifested in the meltpool's characteristics during the build process so as to avoid the production of defective parts and to increase efficiency. At the time I was working at GE Global Research and Tom was the technical and project lead at GE Aviation and then GE Additive. Tom was a pleasure to work with. Communication was easy and he was very knowledgable about the additive materials and equipment. Tom quickly understood the concepts behind the algorithms within the analytics and successfully lead the first project, focused on the feasibility of the analytics, to the second project that was aimed at transforming the technology into a product. I would definitely work with Tom again.
John Kleek, Sr
Before retiring in Jan 2018 from AFRL Materials and Manufacturing Directorate, I worked with Tom at GE on a project that developed sensing technologies and data analytics to better detect defects during powder bed laser fusion processes of nickel alloys and how to overcome the defects. Tom had the expertise and capability to successfully carry out the project both experimentally and programmatically. The project was a huge success thanks to Tom's diligent work and analytics background.
Experience
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Open Additive an ARCTOS group
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United States
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Industrial Machinery Manufacturing
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1 - 100 Employee
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Director of Advanced Additive Manufacturing Technologies (Open Additive)
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May 2023 - Present
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Associate Director of Advanced Additive Manufacturing Technologies (Open Additive)
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Dec 2022 - May 2023
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Director of Research and Technology / Chief Scientist
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Sep 2020 - Dec 2022
Lead team of scientists and engineers to provide open platform LPBF hardware/software solutions for a wide array of customer needs.
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Chief Scientist - AM Technologies
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Feb 2020 - Sep 2020
TRL/MRL development and commercialization of sensing and analytics technologies for laser powder bed machines.
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ARCTOS
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United States
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Investment Management
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Principal Scientist - AM Technologies
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Jul 2020 - Dec 2020
Continuing role from UTC due to an acquisition and rebranding to ARCTOS. TRL/MRL development and commercialization of sensing and analytics technologies for laser powder bed machines. Continuing role from UTC due to an acquisition and rebranding to ARCTOS. TRL/MRL development and commercialization of sensing and analytics technologies for laser powder bed machines.
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Universal Technology Company, LLC
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United States
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Aviation and Aerospace Component Manufacturing
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1 - 100 Employee
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Principal Scientist - AM Technologies
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Sep 2019 - Jul 2020
TRL/MRL development and commercialization of sensing and analytics technologies for laser powder bed machines. TRL/MRL development and commercialization of sensing and analytics technologies for laser powder bed machines.
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GE Additive
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United States
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Machinery Manufacturing
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300 - 400 Employee
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Product Owner for Additive Analytics
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Apr 2018 - Aug 2019
Led product development team for meltpool analytics software to reduce customer costs for additive manufacturing inspections for 2019 revenue target.Headed customer discussions with beta level meltpool monitoring analytics software at Formnext 2018 and Rapid 2019 trade showsPresented meltpool analytics software and use for manufacturing cost reduction at the Additive Manufacturing User's Group meeting 2019 Recognized by industry as subject matter expert on DMLM sensing and analytics technology Manage internal and external communication Show less
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Lead Machine Technology Engineer
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Jan 2017 - Apr 2018
Principle Investigator and Program Manager for contract with US Air Force Research Laboratory to develop an AM process monitoring sensing and analytics solution for availability within the greater AM industrial space. Achieved Air Force Research Laboratory criteria for successful completion of Phase 1 meltpool monitoring analytics program at MRL 6Guided strategy for DMLM process monitoring technology roadmap Designed next generation DMLM process monitoring sensing and analytics system Created and implemented meltpool monitoring analytics software team for commercial software development Show less
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GE Aviation
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United States
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Aviation and Aerospace Component Manufacturing
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700 & Above Employee
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Lead Manufacturing Engineer
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Sep 2015 - Jan 2017
Led DMLM process monitoring development efforts for non-destructive evaluation reduction initiatives.Managed Phase 1 Air Force Research Laboratory Program to develop meltpool monitoring analytics software Programmed Fanuc robots for DMLM post-process automation Led technology evaluation programs for pilot and technology demonstrator meltpool monitoring technology on OEM DMLM machines Created technology insertion plan for implementing meltpool monitoring technology in aerospace manufacturing environment Show less
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R&D Engineer/Technologist
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Dec 2013 - Sep 2015
Led early research and development work for manufacturing cost reduction initiatives leveraging DMLM machines.Principle Investigator for competitive Phase 0 program from Air Force Research Laboratory against two other aerospace OEMs for development of meltpool monitoring sensing and analytics analytics solution- Won Phase 1 award for Air Force Research Laboratory contractLed Joint Technology Development Agreement program \#1 and wrote program \#2 with external collaborator and executed tasks resulting in not to move forward Evaluated prototype meltpool monitoring technology on commercial DMLM machine including prototype data exploration software resulting in decision to move forward Strong collaborator in IP landscaping exercise meltpool monitoring technologies for laser welding and DMLM machines to inform technology development strategy Show less
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Aflac
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Insurance
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1 - 100 Employee
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Benefits Consultant
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Jan 2013 - Nov 2013
Help people when accident or illness presents a financial strain. Help people when accident or illness presents a financial strain.
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Independent Contractor
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United States
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IT Services and IT Consulting
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Groundskeeper/Landscaper
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May 2012 - Nov 2012
Tree removal, land re-scaping, mulching, mowing, fertilizing. Tree removal, land re-scaping, mulching, mowing, fertilizing.
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University of Chicago
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United States
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Higher Education
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700 & Above Employee
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Graduate Research Assistant
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Sep 2004 - Mar 2012
• LabView, Mathematica and Matlab • Design, construction, alignment and maintenance of titanium sapphire lasers, pulse pickers, phase modulation apparatus and optical interferometers • Microscopes, dark field and bright field illumination • Scanning, reflection and transmission spectrometers • CCD cameras, photodiodes/photomultiplier tubes, lock-in amplifiers, fiber optics • Electron gun evaporation/deposition, spin casting, drop casting • Beam scanning apparatus construction • LabView, Mathematica and Matlab • Design, construction, alignment and maintenance of titanium sapphire lasers, pulse pickers, phase modulation apparatus and optical interferometers • Microscopes, dark field and bright field illumination • Scanning, reflection and transmission spectrometers • CCD cameras, photodiodes/photomultiplier tubes, lock-in amplifiers, fiber optics • Electron gun evaporation/deposition, spin casting, drop casting • Beam scanning apparatus construction
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The College of Wooster
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United States
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Higher Education
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700 & Above Employee
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Laboratory Assistant
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Aug 2001 - May 2004
Supervised students in the lab and offered aid in the following courses: Organic Chemistry I and II, Modern Physics and Junior Independent Study.
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Research Experience for Undergraduates
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May 2001 - Jul 2001
Prepare and characterize liquid crystal mixtures via thermal and electrical properties
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Student Intern
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Jun 2003 - Aug 2003
Upgraded the LabVIEW software running on the Ionization Profile Monitors on the Main Injector. Upgraded the LabVIEW software running on the Ionization Profile Monitors on the Main Injector.
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Research Experience for Undergraduates
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Jun 2002 - Aug 2002
Model electron and positron damping rings for accelerator design Model electron and positron damping rings for accelerator design
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Education
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2004 - 2012
University of Chicago
Doctor of Philosophy (Ph.D.), Physics -
2004 - 2005
University of Chicago
Master's Degree, Physics -
2000 - 2004
The College of Wooster
BA, Physics, Chemistry, Mathematics
Community
