Writing
From the
workshop.
Material comparisons, design rules that lower your quote, and what we learn printing and machining other people's parts.
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Case Study
Architecture & Construction: Moving from 2D Blueprints to Physical Massing Models
Manual foam board modeling cannot replicate complex curved facades or urban massing plans. How architecture firms translate BIM and Revit models into presentation-ready 3D prints.
Materials
PEEK and High-Performance Polymers in Additive Manufacturing: Aerospace and Oil & Gas
Exploring polyaryletherketones (PEEK, PEKK, and Ultem): extreme chemical inertness, 250 °C continuous service, and replacing titanium in aerospace and downhole oil tools.
Quality & Inspection
Quality Control in Additive Manufacturing: Caliper Inspections, Go/No-Go Gauges, and CMM
Inside our quality assurance workflow: digital optical comparators, Class X plug gauges for critical hole diameters, and documented First Article Inspection (FAI) reports.
Post-Processing
Dyeing SLS Nylon Parts: Color Penetration, Temperature Control, and Best Practices
Why SLS powder-sintered PA12 parts are ideal for deep dye coloring. Acid bath temperatures, soak times, UV-stable pigments, and why dyed parts resist chipping.
Post-Processing
Vibratory Tumbling and Bead Blasting 3D Printed Parts for Matte Finishes
Achieving unified, non-directional industrial matte textures on FDM and SLS nylon prints using ceramic media tumblers and 60-grit glass bead blasting.
Post-Processing
Acetone Vapor Smoothing for ABS & ASA: Process, Safety, and Dimensional Changes
Transform striation-heavy FDM parts into glossy, injection-molded looks. Chamber setups, exposure timing rules, and protecting critical mounting hole dimensions.
Hardware Prototyping
From Breadboard to Injection Molding: The 4 Prototyping Phases Every Hardware Team Needs
Navigating Proof of Concept (POC), EVT, DVT, and PVT without burning capital. Where 3D printing accelerates each milestone and when hard tooling makes sense.
Hardware Prototyping
Designing IP-Rated Waterproof Enclosures with 3D Printed O-Ring Grooves
Achieving IP65 and IP67 ingress protection with printed housings. Gland cross-section dimensions, 20-30% O-ring squeeze calculations, and post-print pore sealing.
Hardware Prototyping
Prototyping Electronics Enclosures: Cable Relief, Bosses, and Thermal Venting
Essential design rules for custom PCB housings: mounting boss heights, snap-fit tolerance clearances, heat sink airflow passages, and strain-relief cable clamps.
Case Study
Case Study: Custom Ergonomic Jigs and Assembly Fixtures on the Factory Floor
How a consumer electronics assembly facility deployed 18 custom printed alignment fixtures in five days, reducing operator wrist fatigue and cutting assembly errors by 65%.
Case Study
Case Study: Rapid Tooling and Thermoforming Molds Printed in 24 Hours
Replacing $4,500 aluminum tooling with high-temp printed resin mold bucks for medical blister trays, delivering production-grade pilot packaging in 48 hours.
Case Study
Case Study: Redesigning an Industrial Drone Airframe for 40% Weight Savings
How an autonomous survey drone team in Nigeria used chopped carbon fiber nylon and topology optimization to shed 320 grams and extend flight endurance by 14 minutes.