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How Fathom is Bridging the Gap Between Prototype and Production - The Industrial Lens Podcast

On this episode of The Industrial Lens, host Jeremy King sits down with Rush LaSelle, CEO of Fathom Digital Manufacturing, to discuss how the company is helping manufacturers navigate a changing global landscape.

From reshoring and automation to AI-driven design, Rush shares how Fathom’s hybrid model of domestic and global manufacturing empowers companies to scale faster while maintaining both quality and innovation.

The State of U.S. Manufacturing

After years of global disruption, the U.S. manufacturing sector stands at a crossroads. As Rush explains, the Purchasing Managers Index (PMI) sits around 50, signaling an industry in transition where some sectors are thriving while others face contraction.

Yet, the outlook isn’t all uncertain. Growth areas such as defense, electrification, and humanoid robotics are sparking renewed optimism. “There’s a lot of opportunity if you’re focused on the right markets and products,” Rush says. “And that’s where Fathom thrives by helping clients who have great ideas but need the engineering and manufacturing muscle to make them real.”

How Fathom Bridges Prototype to Production

Transitioning from a single prototype to full-scale production is where many companies stumble. Rush calls it “the million-piece challenge.”

Fathom helps customers design for manufacturability from the start rather than just printing a 3D prototype. They also map how that part can evolve into injection molding, machining, or hybrid processes as demand grows.

He shares an example from the aerospace industry, where a customer began with a fully 3D-printed assembly. Fathom’s engineers analyzed cost, performance, and scalability to identify where additive made sense and where traditional processes could reduce cost. The result was a smarter, hybrid manufacturing plan from the start.

“It’s about thinking through the full bill of materials, not just the prototype,” Rush explains.

Why Hybrid Manufacturing Models Are the Future

While “reshoring” gets buzz, Rush stresses that real-world manufacturing rarely means bringing everything back onshore. Instead, companies are adopting hybrid supply chains that combine U.S.-based quality and oversight with lower-cost production steps abroad.

A recent healthcare client illustrates this model. Fathom performed early machining and final inspection in the Midwest but sourced lower-value components overseas, balancing cost and quality while meeting strict regulatory standards.

“It’s not 1950s manufacturing anymore,” Rush says. “It’s about knowing when to produce locally, when to partner globally, and how to make those systems work together.”

What White Glove Manufacturing Support Looks Like

Fathom’s “white glove” approach centers on supplier consolidation and high-touch engineering support. Instead of juggling multiple vendors, customers can work through one team that manages every stage, from CNC machining and additive manufacturing to quality inspection.

That single point of contact reduces schedule risk, cost overrun, and quality issues. Fathom’s engineers also guide customers through design optimization, ensuring drawings and quality specs align with the desired cost model.

“We’re not just a parts provider,” Rush says. “We’re a solutions provider that helps teams get from concept to production efficiently and intelligently.”

The Role of AI and Digital Tools On the Factory Floor

AI and digital manufacturing are already reshaping how teams design and produce. Fathom uses digital systems to move information seamlessly between engineers, project managers, and machine operators to accelerate setup, quality control, and decision-making.

From AI-assisted CNC programming to automated data reporting, Rush sees AI as an augmentation, not a replacement. “Our machinists don’t want to do the mundane setup work,” he says. “They want to make the race car run faster. AI helps them focus on that.”

The same philosophy extends to Fathom’s recruiting strategy. As manufacturing becomes increasingly digital, the company attracts engineers and makers who thrive on problem-solving and curiosity. These are people who want to be hands-on with the next generation of technology.

Listen to the Episode

In this episode, Rush and Jeremy explore:

The true state of U.S. manufacturing and where it’s heading.
How Fathom helps clients scale from prototype to production.
Why hybrid supply chains are here to stay.
What “white glove” manufacturing really means in practice.
How AI is changing engineering and production workflows.

Listen to the full episode on Spotify.

Listen to the full episode on Apple Podcasts.

Learn More About Fathom

Visit FathomMfg.com to explore their manufacturing capabilities, partnerships, and engineering support services.

Follow Fathom on LinkedIn for insights into additive manufacturing, hybrid production, and digital transformation in industry.

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