Commercial Product Case Studies

Realize more opportunities with 3D printing

Commercial manufacturers need the flexibility to make great products in small, medium or large volumes. Digital manufacturing solutions are often the difference between turning down potential business and cost-effectively serving a niche need.

Check out the custom 3D printed microphone that U2 used on tour; large-vehicle HVAC system prototypes; and a clever tooling hack for custom Xerox printers.

Customer

Description

Industry

Technology

1212 Studio

Voeten's team was able to print several design iterations and sections of the microphone in order to examine and optimize the pressure points and light distribution within the rings and between all the components. Voeten was so satisfied with the quality and strength of the printed FDM parts, he optimized the design so they could be used as final parts on the U2MICs. 

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Commercial Products

FDM

Artem Chipotle

With an approved animatic (a design file with rough-draft animated sketches), Thorne and his team simply fed that data to the Dimension 3D Printer, which produced the models in just a few hours. 

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Commercial Products

FDM

Aviradyne

The D-DAC method relies on 3D-CAD driven additive fabrication technologies like FDM to produce parts. 

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Commercial Products

FDM

Balda Solutions

Balda Solutions Malaysia, a mobile phone parts manufacturer, shaved off three to six weeks from its design cycle by incorporating an in-house Objet Eden 3D Printer, helping its customers get products in consumers’ hands much faster.

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Commercial Products

PolyJet

Baldor

Baldor is now using the Dimension 3D Printer to test form, fit and function for a variety of design applications including mounting brackets for motors, stationary switches for motors, conduit boxes, fans and breaks. 

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Commercial Products

FDM

Bassler

One of the first projects Bassler completed using the Dimension 3D Printer was a tabletop holder for e-readers, such as the Amazon Kindle. 

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Commercial Products

FDM

Bell & Howell

Like a number of progressive companies, Bell & Howell has made steps into the area of rapid manufacturing parts using the FDM system. 

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Commercial Products

FDM

BlueSky

In 2006, BlueSky purchased a Dimension 3D Printer to more easily and cost-effectively develop and test concepts. 

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Commercial Products

FDM

Bullard

During the development of the T3, Bullard brought tighter control to its development process and eliminated the high cost of outsourcing by installing a fused deposition modeling (FDM®) system from Stratasys. With the help of FDM, the company reduced modeling costs by over 80%. 

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Commercial Products

FDM

CammPro

CammPro, a 3D printing service bureau, saved 75 percent of time and cost by upgrading to a Connex 3D Printer over traditional prototyping methods. The machine’s versatile use of multiple materials, hardnesses and design qualities improved customer satisfaction as well.

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Commercial Products

PolyJet

Christie Digital

“Build, test, optimize. That is our motto,” said Mark Barfoot, senior manager for Christie Digital Systems, which manufactures advanced digital projectors and displays. That philosophy of constant improvement drives Christie’s innovative prototyping program.

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Commercial Products

FDM and PolyJet

Diebold

Automated teller machines must safeguard and dispense cash in harsh and abusive conditions. When Diebold, Incorporated designs an ATM, it relies on the FDM process to prove out the design. With FDM, Diebold builds working ATM prototypes with components tough enough for machine-function tests. 

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Commercial Products

FDM

Digital Mechanics

FDM (fused deposition modeling) process for both prototyping and manufacturing of the revised gripper. 

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Commercial Products

FDM

Doosan Infracore

Doosan Infracore sped up the design process for its excavation equipment with an Objet Eden 3D Printer, and won a Red Dot Competition award for one of its 3D printed designs.

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Commercial Products

PolyJet

Ecoinvent

FDM offered the best combination of functionality and cost efficiency to meet Ecoinvent’s unique requirements. 

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Commercial Products

FDM

FDM polycarbonate

As part of R & D for the Stratasys FDM Titan rapid prototyping system, several Beta sites were commissioned to test the equipment in their process. One industrial product manufacturer ended up using the Titan in a way it never anticipated. The Beta site was busy building various polycarbonate prototypes when a belt sander on its production line went down. 

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Commercial Products

FDM

Graco

Graco built functional ABS models from parts produced on the Dimension 3D Printer for lab and field testing. 

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Commercial Products

FDM

Grohe Water Technology

Before discovering the Dimension 3D Printer, it was much more time and cost consuming using Grohe's toolmakers or external suppliers to produce prototypes. During the first four months of use, the Dimension 3D Printer ran for more than 380 hours. In contrast, a milling cutter, installed at the same time, was used only a couple of hours. 

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Commercial Products

FDM

Indian Springs Manufacturing

Indian Springs Manufacturing Company, Inc has a long history of helping businesses move forward through design and manufacturing. Based in Baldwinsville, NY, Indian Springs is a contract manufacturing company specializing in CNC machining and manufacturing. 

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Commercial Products

FDM

Industrial Scientific Corporation

With the Dimension 3D Printer, Owens and his team can now keep more people within the company updated about a project’s progress and give decision-makers more opportunities to interact with the designs. 

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Commercial Products

FDM

Ioxus

The impact of the Dimension 3D Printer on the two businesses has been dramatic. 

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Commercial Products

FDM

Kirby Morgan

By bringing 3D printing capabilities in-house, they sought to cut model production time and to obtain complete control over the product design process. 

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Commercial Products

FDM

MSA AUER

MS AUER product managers know exactly what their customers need and handle order placement in-house. Models made of ABS plastic enable them to quickly determine whether the product meets market requirements. 

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Commercial Products

FDM

Neptec

Using a Dimension 3D printer, Neptec was able to use the three-dimensional information from the LCS to print a 3D model of the damage aboard the Endeavour. 

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Commercial Products

FDM

NorSap

The technology has changed the way SAP works.

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Commercial Products

FDM

Parvus

With the Dimension 3D Printer, Parvus designers avoided a number of productivity bottlenecks and completed modeling approximately 80 percent faster than using CNC milling. 

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Commercial Products

FDM

Peltor AB

Peltor AB creates attractive, accurate prototypes of its hearing protectors and communication devices that function realistically and enable designers to verify the final products before mass production.

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Commercial Products

PolyJet

Rapid Models and Prototypes

RM&P added fused deposition modeling (FDM) rapid prototyping to its services a few years ago, and Pizzo says it has greatly expanded the company’s capabilities. 

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Commercial Products

FDM

RedDOT — FDM Nylon Prototyping

HVAC system designer RedDOT couldn’t easily prototype nylon parts in-house, and corrections delayed production by six weeks and cost $100,000. Adding FDM Nylon 12 to its materials options allowed RedDOT to build functional prototypes fast and easily.

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Commercial Products

FDM

RedDOT — ULTEM 9085 Prototyping

RedDOT designs and builds mobile heating, ventilation and air conditioning (HVAC) systems and components for on- and off-highway vehicles including commercial trucks and vehicles used in construction, agriculture, military and other demanding applications. 

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Commercial Products

FDM

Servco

Servco used an Objet30 Pro 3D Printer with PolyJet technology to prototype its Eagle product, a mobile, flexible lab furniture system. Increased prototyping capabilities through in-house 3D printing halved the expected time to market while ensuring design confidentiality.

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Commercial Products

PolyJet

Stratasys Manufacturing

Since employing FDM to create fixtures at Stratasys, the manufacturing engineering department is responding faster and increasing its productivity. 

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Commercial Products

FDM

Swany

Swany Company Ltd. used its new Objet Connex 3D Printer to transition from a flagging manufacturing business to powering new product design. Now the company works with 200 companies with product planning, conceptual design and prototyping.

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Commercial Products

PolyJet

Thermal Dynamics

Although the Fortus system was put to work building prototypes, engineers quickly realized its potential for direct digital manufacturing. 

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Commercial Products

FDM

Thogus Products

FDM touches every aspect of business at Thogus. “We have automation, robots on our machines. Rather than using a steel plate or aluminum frame for big, heavy end of arm tools that are expensive and take long time to build, we can take 3D geometry and print an end of arm tool that weighs 70 – 90% less. And we can do it in less than 24 hours.” 

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Commercial Products

FDM

University of Budapest

To perform the tests the team needed an efficient, inexpensive method of producing injection molded prototypes from the same material that would be used to create the final product. However, conventional methods of producing injection molds are often painstaking, highly expensive and time intensive — all of which were factors the team could not afford. So Dr. Kovács turned to the Objet350 Connex™ 3D Printer from Stratasys®.

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Commercial Products

PolyJet

Western Tool & Mold

The strength of its Fortus 3D Printer – and the ULTEM 9085 resin it uses – enabled manufacturer Western Tool & Mold to quickly validate injection molding designs, even out workflows and strengthen customer relationships.

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Commercial Products

FDM

Wincor Nixdorf

With the Dimension 3D Printer, Wincor Nixdorf's product development team is now able to present solutions to their customers quickly, developing products within a few days. 

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Commercial Products

FDM

Wood Group

In less than three months, Wood Group was able to develop functional models in-house for more than 100 components, a feat that would have cost thousands of dollars and taken much longer using outside service providers and less advanced technology. 

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Commercial Products

FDM

Xerox (networking)

The Xerox design team looked to the Dimension 3D Printer to help improve their efficiency at producing prototype parts by moving away from the traditional 'machining' function and moving more cutting edge 3D printing equipment in house. 

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Commercial Products

FDM

Xerox (thermoforming)

Xerox originally purchased a Fused Deposition Modeling (FDM) machine primarily to produce prototype parts, but soon realized that it was also the ideal tool for fixtures and assembly tooling for use in its manufacturing processes. 

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Commercial Products

FDM

Xerox (tooling)

Xerox needed 350 connectors modified immediately for testing. “We have used FDM to make many different types of tooling, so I started thinking of how I could utilize FDM to make tooling to modify the connectors,” Byerley said.  

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Commercial Products

FDM

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