We are the largest independent Additive Manufacturing Engineering Consultancy. Learn more about our team below.


John E. Barnes

John E. Barnes

John E. Barnes - Founder and Managing Director

John has a 25+ year career in product development and aerospace with Honeywell, Lockheed Martin Skunk Works™, Australia’s CSIRO, and Arconic (formerly Alcoa and RTI International Metals). He’s been involved in metal additive manufacturing throughout this career beginning in the late 1990s where he was part of the Sandia National Labs LENS™ CRADA. Since then, he has been in and around AM working both technical and business cases for implementation and development efforts in materials, powders, processing, and printing to mature the technology for applications. John is recognized internationally for contributions to additive manufacturing, product development, and leadership in engineering. His groups boast world firsts in medical, therapeutic, and aerospace additive manufacturing. John is a Materials Engineer by background but has developed expertise in manufacturing, airframe structures, gas turbines and low observables. He is currently an Adjunct Professor at RMIT University, and an Adjunct Senior Research Fellow at Monash University, both in Melbourne, Australia.  In 2014, he was Purdue University’s Materials Engineer of the Year, and in 2017, he was invited to join the Additive Manufacturing Technical Community as a  SME Advisor based upon active industry contributions, reputation, and personal commitment to expand the use of additive manufacturing.

Reach John by e-mail at John@thebarnes.group.

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John is located in Pittsburgh, Pennsylvania.


The team

Christopher Aldridge

Christopher Aldridge

Christopher Aldridge

Chris started his career at Lockheed Martin’s Skunk Works focusing initially on additive manufacturing (AM) technology development, characterization and implementation for aerospace applications. He went on to lead and then manage engineering design teams for deepwater oil and gas production and intervention equipment before returning to the AM industry at Arconic (formerly Alcoa) Titanium & Engineered Products, with the responsibility of managing research and development activities for additive manufacturing at Arconic’s production facility in Austin, Texas. 

Reach Chris by e-mail at Chris@thebarnes.group.

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Chris is located in Austin, Texas.

Kirk Rogers, PhD

Kirk Rogers, PhD

Kirk Rogers

Dr. Rogers has used additive technologies to solve manufacturing, repair & supply chain problems for the last 10 years. He recently was the technical leader on the startup of a $40M Additive Manufacturing R&D center, the culmination of a nearly 20-year career at GE. The majority of Kirk’s career has been in the medical device manufacturing realm, where he built manufacturing lines for and qualified numerous products. Dr. Rogers has 25 years of experience in materials processing and business strategy including metal powder production, novel joining methods, metal additive manufacturing, novel refractory alloys, sustainable manufacturing, carbon composite materials, powder metallurgy, technology portfolio management, identification and application of new process methodologies; and development of patent and technology strategy. A technical innovator, and adept thinker, Kirk has obtained 3 US patents, and has filed more than 20 trade secrets and patent applications. Kirk obtained his B.S. Materials Engineering from Case Western Reserve University, and Ph.D in Materials Science and Engineering from Purdue University. He completed postdoctoral work at The Ohio State University and is a certified Six Sigma Blackbelt.

Reach Kirk by e-mail at Kirk@thebarnes.group.

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Kirk is located in Youngstown, Ohio.

Kevin Slattery, DSc

Kevin Slattery, DSc

Kevin Slattery

Dr. Slattery was most recently the Chief Scientist for Additive Manufacturing in Boeing Research and Technology (BR&T). He was responsible for developing and integrating the technical roadmaps and development plans for metallics AM for the entire company, along with building and leading a multi-skilled team to execute and deliver the technology throughout the enterprise. Prior to that, he was the Chief Scientist for Metals, Ceramics, and Mechanical Systems in BR&T, with responsibility for portfolio development and coordination, while executing the additive manufacturing portion. He served at the Division Chief Engineer for USN & USAF fighters and US Army rotorcraft in Boeing’s Military Sustainment organization, including international operators. From 1997 to 2012, he was on the BR&T Metals Team as a researcher and senior manager, where he primarily developed advanced low-cost titanium processing technologies supporting all Boeing products. He was the technical and programmatic lead in implementing the first in aerospace metal additive manufactured structural aircraft components for both spares and production, along with 5 other first in the industry technology implementations. Kevin currently holds 34 US patents, with another 15 applications pending. Kevin has B.S. and M.S. degrees in Metallurgical Engineering from University of Missouri-Rolla (now Missouri S&T), and a DSc in Material Science and Engineering from Washington University in St. Louis.

Reach Kevin by e-mail at Kevin@thebarnes.group.

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Kevin is located in St. Louis, Missouri.

Laura Ely

Laura Ely

Laura Ely

As the Head of Technology at GKN Aerospace, Laura developed the strategic skills required to affect technological change in large organizations. This includes translating technical roadmaps into strategic business visions and vice versa, building businesses cases, securing capital and operating funding (~$15M OpEx and ~$7M CapEx over 4 years), protecting and exploiting Intellectual Property, and collaborating across the industrial supply chain. Laura’s leadership skills are highlighted through her ability to build and enable diverse teams; she was responsible for the build out of a new team focused on the maturation of laser/wire deposition for Titanium aerostructures after negotiating a CRADA between GKN Aerospace and Oak Ridge National Laboratory, valued at $18M over 5 years. 

Laura has a passion for optimizing manufacturing processes. For 15 years, she has focused on improving metallic alloys and processes, specifically for laser/wire deposition, friction stir welding, spin forming, machining, and various wrought processes with application to Titanium aerostructures, Aluminum wing skins and inlet lip skins, and Copper electrical connectors, coinage, and ammunition. She directly supported aerospace production including Boeing’s 787-9, F/A-18 and F-15. Her enthusiasm for additive manufacturing and promoting diversity in the workplace is contagious, and Laura shares her energy via various public forums, ranging from executive aerospace conferences to university lectures to kindergarten classrooms. Laura graduated summa cum laude with her B.S. in Metallurgical Engineering from the University of Missouri – Rolla (now Missouri S&T).

Reach Laura by e-mail at Laura@thebarnes.group

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Laura is located in St. Louis, Missouri.

Chelsea Cummings.png

Chelsea Cummings

Chelsea began her engineering career at Honeywell Aerospace more than five years ago, gaining experience in various roles, including additive manufacturing. Her AM experience focused on development of metal parts built on powder bed machines for aerospace applications. Her experience qualifying production parts for AM with the FAA at Honeywell led her to a role in new product engineering at Arconic (formerly Alcoa) where she successfully qualified additively manufactured parts for aerospace production for a major aircraft manufacturer, and others. Her work with various manufacturers for flight and space has honed her AM design skills for diverse applications. Lean certified by both her alma mater, Arizona State University, and Honeywell, she cultivates streamlined AM designs, production, and applications. 

Reach Chelsea by e-mail at chelsea@thebarnes.group.

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Chelsea is located in Austin, Texas.

Bruce Mclean

Bruce Mclean

Bruce Mclean

Bruce has broad qualifications and experience in Aircraft Engineering with both the New Zealand and United Kingdom Royal Air Forces – including A&P Mechanic, Aeronautical Diploma, Honours Degree in Mechanical Engineering and a post-graduate Aero-Systems Engineering Degree.

More than half of his 40+ years of professional experience has been in aviation related industries – both military & commercial airline operations, maintenance, repair & overhaul and design.  Additional experience in Global Supply Management of high technology commodities with John Deere Construction & Forestry Division. More recent development experience with a suite of surface modification technologies associated with thin-film ceramic coatings - PVD/ CVD/ DLC, ion implantation and plasma spray thermal coating equipment development whilst with Page-Macrae Engineering.

Bruce was a founding partner and the Senior Engineer with Zenith Tecnica in New Zealand since early 2014 which led to the successful commercialization of Electron Beam Melting Additive Manufacturing for the aerospace, space, motorsport, medical and marine sectors amongst a global customer base.  Consequently, Bruce has established a worldwide reputation as a technology and industrialization specialist with Electron Beam Melting Additive Manufacturing technology. 

Reach Bruce by e-mail at Bruce@thebarnes.group.

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Bruce is located in Waikato, New Zealand.

Tim Simpson, PhD

Tim Simpson, PhD

Tim Simpson

Tim has more than 20 years of experience using and teaching students, designers, and engineers about 3D printing and AM. As Co-Director of Penn State’s Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D, www.cimp-3d.org), Tim has been at the leading edge of the recent wave of AM innovation and industry adoption, and he has extensive experience with powder bed fusion, directed energy deposition, and non-destructive inspection technologies. He specializes in Design for Additive Manufacturing, and he has helped train and educate more than 600 industry practitioners to realize AM’s unique value proposition in aerospace, automotive, consumer goods, defense, energy, medical, oil and gas, and space industries. He was on the founding team of America Makes and spearheads multiple workforce, education, and outreach efforts at all levels across the country. He currently is the Paul Morrow Professor of Engineering Design and Manufacturing at Penn State and is a monthly contributor to an AM column in Modern Machine Shop.

Reach Tim by e-mail at Tim@thebarnes.group.

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Tim is located in State College, Pennsylvania.

Michael Hickner, PhD

Michael Hickner, PhD

Michael Hickner

Mike has been a polymer scientist for more than 15 years with in-depth activities in polymer chemistry, structure-property relationships, characterization, and processing of polymers. He is a Co-Director of Penn State’s Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D, www.cimp-3d.org), and Associate Director of the Materials Research Institute with particular interests in analytical materials measurements on additively manufactured components. He currently spearheads CIMP-3D’s efforts in advanced polymer and composite additive manufacturing with emphasis on new materials in AM, high-strength parts, and new processing approaches. He directs a research group of 15 students and professionals focusing on polymer chemistry, alternative energy and clean water technology, and additive manufacturing of polymeric materials by a variety of routes including photopolymerization, liquid and thermal extrusion, and laser processing. He currently is an Associate Professor at Penn State he holds 10 patents and has co-authored more than 160 peer-reviewed publications that have been cited more than 14,000 times. 

Reach Mike by e-mail at Mike@thebarnes.group.

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Mike is located in State College, Pennsylvania.

Rob Higham

Rob Higham

Rob Higham

Robert started his career at BAE Systems as an aeronautical engineer before moving on to BMW. He moved from motorsports engineering back to aerospace and spent time with Airbus in the UK and Germany where the additive manufacturing research, development, and industrialization work began. While with Airbus, Robert was an additive manufacturing specialist, specifically focused on powder bed fusion and powder handling. He put systems in place to manage the electron beam melting process for additive manufacture and the powder handling requirements. He currently works in academia and teaches motorsports engineering in the north west of England at the National Centre for Motorsports Engineering in addition to working as a specialist consultant and supporting The Barnes Group Advisors. He went to university as a mature student and graduated with a first class degree with honours in Motorsports Engineering.

Reach Rob by e-mail at Rob@thebarnes.group.

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Rob is located in Burscough in Lancashire, United Kingdom.

Tierney Barnes

Tierney Barnes

Tierney Barnes

Tierney has 20 years experience in various roles of Business Management. The majority of her career was spent at The Coca-Cola Company where she managed projects relating to IT systems implementations, database development, and process improvement. In the later years at The Company, Tierney was responsible for marketing procurement initiatives which included forecasting, developing and executing purchasing strategies, and global contract negotiation. While living in Australia with her family, Tierney worked as an Operations Consultant for GNC Group Consulting, in Melbourne. She holds an BA in Marketing from Southern Methodist University and a MBA from Georgia State University in Marketing and Decision Science.

Reach Tierney by e-mail at Tierney@thebarnes.group.

Connect with Tierney on LinkedIn.

Tierney is located in Pittsburgh, Pennsylvania.