Case Study: Crossing the Valley of Death in Digital Manufacturing
About Nathan Diller
Nathan Diller brings a rare combination of operational military experience, government innovation leadership, and private sector execution to the defense technology ecosystem. After 22 years of Air Force service as a test pilot, he transitioned to become Director of AFWERX, where he managed and expanded the SBIR budget, helping hundreds of startups navigate government contracting. His subsequent role on the House Appropriations Defense Subcommittee staff gave him legislative perspective on defense budgeting and acquisition. Now, as Head of Aerospace & Defense at Divergent, he’s applying this comprehensive understanding of the ecosystem to scale manufacturing innovation here in America.
About Divergent
Divergent has created the Divergent Adaptive Production System (DAPS), an end-to-end software and hardware production system for industrial digital manufacturing. The company’s approach combines digital engineering for structural optimization, software-driven printable design, efficient 3D printing with optimal part stacking, and robotic assembly. Initially proven in the automotive sector (building the world’s fastest production car at 253 mph), Divergent is now applying this technology to aerospace and defense applications. The company has raised approximately $700 million and maintains partnerships with automotive giants like Aston Martin, Bugatti, and McLaren, as well as defense contractors like General Atomics.
Key Takeaways
Build Credibility Before Asking for Trust: Rather than asking aerospace customers to take leaps of faith on unproven manufacturing processes, Divergent first established extensive qualification datasets in the automotive industry. Working with prestigious brands like Aston Martin and McLaren created a foundation of trust and technical validation that transferred to aerospace applications. This methodical approach to building credibility through data is essential for safety-critical industries.
Position Government as Innovation Partner, Not Just Customer: Instead of viewing government agencies as traditional procurement customers, Divergent saw them as partners in reducing technical, regulatory, and financial risk. Nate emphasizes working directly with government laboratories on airworthiness qualification and regulatory approval processes. This partnership approach opens up highly regulated markets that would otherwise remain closed to innovative manufacturing methods.
Navigate Qualification Through Incremental Value Creation: The path to qualifying 3D printed aerospace parts requires starting with non-safety-critical applications and systematically working up the value chain. Divergent began with items like C-130 hubcaps before progressing to more complex and safety-critical components. Each successful qualification creates an “artifact” that supports the next level of applications, building a comprehensive case for regulatory approval.
Design for Adaptability: Traditional manufacturing requires building “bespoke factories for every system,” creating massive capital expenditure with limited flexibility. Divergent’s adaptable production system can manufacture completely different products on the same equipment, creating both capital efficiency and strategic uncertainty for adversaries. This adaptability enables rapid scaling and pivoting between different applications and customers.
Leverage Cross-Industry Applications for Risk Mitigation: By maintaining operations in both automotive and aerospace sectors, Divergent can aggregate demand, share development costs, and reduce risk across multiple markets. The company’s ability to “print hypercar frames in the morning and cruise missiles in the afternoon” demonstrates how cross-industry applications can create more resilient business models and faster technology development cycles.
For more on Divergent: https://www.divergent3d.com/
For more Crossing the Valley: valleycrossers.com
Follow Nate: https://www.linkedin.com/in/nathan-p-diller/
