In this episode, we sit down with 3D printing veteran Lee Dockstader, whose multifaceted career has spanned major players like 3D Systems and HP. Lee brings a wealth of stories and industry wisdom, from launching stereolithography in Asia to building commercial markets for emerging technologies, as well as transformative moments in dental, hearing aid, and medical device applications of 3D printing. This conversation unpacks industry evolution, breakthrough commercializations, hard-won lessons, and Lee’s perspective on the future of mass personalization in healthcare and beyond.

⚠️ Disclaimer:

This podcast is for educational and informational purposes only. The views expressed do not constitute medical or financial advice. The technologies and procedures discussed may not be commercially available or suitable for every case. Always consult with a licensed professional.

About Our Guest

Lee Dockstader

Lee Dockstader began his career at HP in 1982 and went on to spend more than four decades advancing additive manufacturing across healthcare and other industries. He served as Vice President at 3D Systems, leading business development in dental and healthcare, before returning to HP as Director of Vertical Market Development for its 3D Printing and Digital Manufacturing business, where he focused on production applications for Multi Jet Fusion across medical, dental, life sciences, and other sectors. Lee has presented internationally on medical and dental 3D printing, including keynote-level talks at leading industry conferences and remains an influential voice on the commercialization of 3D printing technologies.

Key Takeaways

• Lee has over 30 years of experience in 3D printing, working with major companies like HP and 3D Systems.
• The dental industry, particularly Align Technology, has revolutionized clear aligner production through the use of 3D printing.
• Medical applications, such as surgical guides for knee replacements, have seen significant adoption.
• Consumer applications, such as eyewear and hearing aids, show promise but face challenges in market adoption.

Lee’s Career Background

• Began career in electrical engineering before transitioning into CAD/CAM
• Worked at HP in Asia for 3 years in the late 1980s, expanding regional operations
• Joined 3D Systems in 1997, helping to launch and grow their presence in Asia
• Returned to HP to lead 3D printing market development, focusing on healthcare, dental, and life sciences
• Presented internationally at AMUG, the Additive Manufacturing Summit, and other industry events
• Advises healthcare startups on commercialization, market entry, and scaling

Dental Industry Revolution

• Align Technology partnered with 3D Systems to scale production of clear aligners
• Took a decade to become profitable, shifting target market from orthodontists to general dentists
• Now one of the largest producers of custom 3D printed parts globally
• Dental market remains difficult for startups due to dominance of established players

Medical Applications

• 3D printed surgical guides for knee replacements adopted in ~20% of procedures
• Saves surgeons 20–30 minutes per case, reducing patient anesthesia exposure
• Key players include Conformis and Stryker for implants, Materialise for surgical planning software
• Challenges include FDA approval timelines, required surgeon training, and post-processing complexity

Consumer Applications

• Hearing aid industry’s full shift to 3D printing in early 2000s cut remake rates from 20% to 5%
• Transformation enabled by digital scanning, specialized resins, and high-precision printers
• Eyewear has strong potential for disruption with perfect custom fit and lower tooling costs, but supply chain and incumbent resistance slow adoption
• Custom 3D printed earbuds could challenge AirPods by offering personalized fit and comfort

Future Outlook

• Eyewear industry presents major opportunity for mass personalization via 3D printing
• Dental applications expanding into more complex restorations and prosthetics
• Regulatory hurdles will continue to slow adoption in custom medical devices
• Potential growth in adjacent areas like jewelry and molded fiber packaging technology

Industry Advice

• Persistence is critical; many technologies take a decade or more to find mainstream traction
• Seek out industry champions who can influence adoption
• Maintain multiple projects in parallel to improve the odds of a breakthrough

Resources & Follow-up:

🔗 Related Companies & Technologies

• 3D Systems
• HP (Hewlett-Packard) 3D Printing
• Align Technology (Invisalign)
• IronCAD 
• Conformis
• Materialise (Dental and Surgical Guides)
• Stratasys (general 3D printing technology)
• Stryker (medical implants)
• Dentsply Sirona (Dental CAD/CAM & materials)
• 3Shape (Dental & hearing aid scanning/software)
• Exocad (Dental CAD software)
• Carbon (3D printing with dental resins)
• Vizua3D

🔗 Industry Events & Other References

• Global 3D Printing Summits (Jenny’s reference to hosting industry events)
  • If referencing 3DHEALS: https://www.3dheals.com/
• FDA Regulations for 3D Printed Medical Devices
• Restore 3D (acquirer of Conformis)

Contact Lee Dockstader

🌐 Linkedin