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Carl Calabria leaves Formlabs, joins Digital Alloys as CTO

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Digital Alloys, a Massachusetts-based 3D printing company, has announced the appointment of Carl Calabria as its new Chief Technology Officer (CTO). Calabria has worked in the additive manufacturing industry for years, holding positions such as the Head of Engineering at Formlabs, and engineering leadership positions at Markforged, iRobot, Sonos and Avid. At Digital Alloys, Calabria will help the company to accelerate the commercial release of its Joule Printing metal AM technology.

Digital Alloys has developed a novel AM process called Joule Printing, which it describes as a “radically simple new metal additive manufacturing technology that delivers hard metal parts at the highest speed and lowest cost.” The main cost influencing factor in the Joule Printing process is that it uses commodity wire as raw material. The wire is positioned and extruded from a feed system, at which point it is melted using joule heating (resistance heating). This process is continued as the print head moves, resulting in dense metal components.

Last year, Digital Alloys raised $12.9 million in a Series B funding round that saw investments from G20 Ventures, Boeing HorizonX Ventures, Lincoln Electric and existing investor Khosla Ventures. With Calabria joining the Digital Alloys leadership team, the company hopes to accelerate the commercialization of its Joule Printing technology.

“Attracting Carl to Digital Alloys was a coup for us,” said Duncan McCallum, CEO of Digital Alloys. “He brings extensive experience commercializing additive manufacturing and other cutting-edge technologies, and has a track record of building and leading strong organizations.”

Carl Calabria Digital Alloys

In his new position, Calabria will be responsible for both research and engineering at Digital Alloys. Elad Taig, the Vice President of Engineering at Digital Alloys, will continue to lead the company’s engineering organization.

“Leaving Formlabs was a difficult decision,” said Calabria. “But I was drawn to the size of Digital Alloys’ market, the team, and the opportunity to use Joule Printing to deliver metal printing solutions that have the speed, cost and quality needed for volume manufacturing of larger parts. The remarkable technology is producing titanium and tool steel parts faster, and at lower cost than conventional manufacturing processes.”

Calabria was the Head of Engineering at Formlabs for just over a year. Prior to that, he served as VP of Engineering at Superpedestrian and the Executive VP of Engineering at Markforged.

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Tess Boissonneault

Tess Boissonneault is a Montreal-based content writer and editor with five years of experience covering the additive manufacturing world. She has a particular interest in amplifying the voices of women working within the industry and is an avid follower of the ever-evolving AM sector. Tess holds a master's degree in Media Studies from the University of Amsterdam.

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