A look at real client builds — the challenge, our approach, and the final result.
A 50-unit production run needed brackets with smooth aerodynamic surfaces and tight mating tolerances to a carbon spar.
ABS parts vapor-smoothed to remove layer drag, with heat-set inserts for repeatable spar attachment. Batch oriented to share support material.
Surface roughness reduced below Ra 1.6 µm; full 50-unit run delivered in 6 days.
Enclosure required UV stability, weather sealing, and a branded cosmetic finish for a field-deployed sensor array.
ASA selected for UV resistance, vapor-smoothed for seal integrity, then paint-finished with the client brand color and clearcoat.
Passed 500-hour UV exposure test; 200 units deployed across 4 climates.
A low-volume turbine blade needed a casting pattern with a smooth, defect-free surface to produce a clean ceramic shell.
PLA pattern printed at 0.1 mm layer height, then hand-finished and sealed to investment-casting standard. Split into two halves for shell removal.
Pattern produced a flawless ceramic shell; final cast blade met dimensional spec.
A set of assembly jigs needed precise cable routing, snap-fits, and thread inserts across 12 different fixture variants.
PETG fixtures with embedded heat-set inserts, living-hinge cable clips, and consolidated multi-variant print scheduling to cut setup cost.
Per-unit fixture cost cut 38% versus machined equivalents; full set delivered in 4 days.
Have a complex project? Let's solve it together.
Request Engineering Support