Building Resilient, Flexible Manufacturing with Carbon’s Jason Rolland
Key Takeaways
Flexibility beats scale: Digital platforms let you adapt faster than traditional tooling.
Resilience is local: Smaller, distributed production reduces tariff and logistics risk.
Performance pays for change: Users will invest in new processes when parts clearly outperform.
For manufacturers considering additive right now
Start with one high-impact part where performance and resilience gains are measurable.
Challenge assumptions: Customization is possible in more industries than you think, and costs may be lower than expected.
Talk early, test quickly: A short conversation can reveal whether additive is viable for your product.
When I first met the Carbon team at Formnext, what struck me wasn’t flashy prototypes — it was finished products. Helmets, bike saddles and cushions already in use. That grounded realism defined my conversation with Jason Rolland, SVP Materials at Carbon: additive that isn’t a side project, but a tool for resilient, flexible, performance-led manufacturing.
We recorded in late June 2025, against a backdrop of volatile tariffs, supply chain disruptions, and unpredictable demand. I asked Jason: how can manufacturers keep production steady in a world that won’t sit still?
Flexibility and localization: the Carbon perspective
Jason set out two ideas at the core of Carbon’s approach:
Flexibility by design
Traditional injection molding locks you in once tooling is set. Carbon’s digital platform — tying together lattice design, elastomeric materials, and software — allows parts to change without retooling.
Localized production
Distributed capacity makes it easier to adapt when tariffs or logistics shift.
“You can keep your inventory in the cloud as a digital space… rather than physical parts.” — Jason Rolland
Carbon positions itself less as a machine vendor and more as a partner in resilience. The model isn’t about dropping off a printer; it’s about working alongside manufacturers to co-develop parts that stand up to disruption.
Why performance is the entry ticket
The “cool factor” of 3D printing has faded. For Carbon, adoption now rests on clear performance advantages.
Helmets (American football): Carbon’s lattice liners improve impact absorption, heat management, and comfort, earning the top four spots in the NFL’s independent helmet rankings.
Bike saddles: Tuned lattices reduce sit-bone pressure and improve comfort — critical for professional cyclists and casual riders alike.
Wheelchair cushions: Breathable, supportive lattices reduce the risk of sores, a serious medical concern.
Across these cases, Carbon has replaced foam with lattices that are customizable, comfortable and durable.
“We’re looking to replace foam and provide a better experience for the user and better performance overall for the part.” — Jason
Resilience in practice: the COVID pivot
Perhaps the clearest demonstration of flexibility came during the pandemic. Carbon repurposed a midsoles production line into diagnostic swabs within days, producing over a million units. The same printers, the same line — just a new resin and a rapid design sprint.
“In a matter of a week or two… we were able to take this very flexible production line and make drastically different products that were needed immediately.” — Jason
That agility speaks to more than additive — it’s about how digital platforms can retool instantly when demand changes.
Sustainability that supports the bottom line
Carbon’s sustainability story is pragmatic: improvements that save money and reduce waste.
Solvent-free cleaning: An industrial “salad spinner” reclaims resin and avoids hazardous waste disposal, cutting cost and environmental impact.
Bio-based materials: Shifting some polyurethanes from petroleum to plant-derived inputs lowers carbon footprint and, in some cases, improves performance (used in Adidas 4D products).
“I’m a big believer in incremental progress… align sustainability objectives with economic objectives.” — Jason
The message: progress sticks when it supports both environmental and business goals.
Carbon’s co-development model
Adoption often stalls when companies are left to figure out additive alone. Carbon avoids that trap by co-developing applications.
Instead of selling a printer first, Carbon often works with manufacturers to design parts, then scales through trusted contract manufacturers. This approach lowers risk and ensures the business case is clear before investment.
“It’s not enough to just drop a machine off… we have a team of applications engineers that will get in side-by-side with the customer.” — Jason
This model frames Carbon less as a vendor and more as a partner in business change.
What I’m taking away
Digital = resilience: Cloud inventory and distributed factories help manufacturers react faster than fixed tooling.
Performance drives adoption: Helmets, saddles, and cushions show that when parts outperform, markets follow.
Sustainability is pragmatic: Waste reduction and bio-based inputs win when they cut cost too.
Partnership is key: Carbon’s co-development approach de-risks adoption and accelerates results.
As Jason put it:
“This is just a tool — like any manufacturing tool it’s got things it can do, things it can’t. It’s about finding the fit.”
Want to Dive Deeper?
This article shares highlights from my conversation with Sofia Peruzzo on the Agents of Change podcast. To hear the full discussion — including more examples and practical insights — watch the full episode here or find the podcast on Apple, Spotify and Amazon.
