Featured Case Study
Banjo Axle
With automakers looking to improve gas mileage and performance, axle supplier and prototype shop team up to produce lightweight, strong units for future pickup trucks....
- Development Time
- Ten weeks
- Processes Used
- Prototype tooling, stamping, laser cutting, machining, robotic welding
- Materials Used
- Basis and high strength steels
- Industry
- Automotive
Slow Cooker Grill
With the deadline for new product introductions approaching, Coleman® turns up the heat for slow cooker prototypes—rapid prototyping specialist fuels a fast response....
- Development Time
- Three weeks
- Processes Used
- Forming, laser processing, stamping
- Materials Used
- Aluminum, steel
- Industry
- Recreational Equipment
Ford Truck Dealer Display
In this day and age, since the time Ford Motor first introduced its tag line ‘Built Ford Tough’ to designate its F-150 Series of pickup trucks, every vehicle maker is out to demonstrate...
- Development Time
- Five Weeks
- Processes Used
- Injection molding, prototype tooling, rapid prototyping, reverse engineering
- Materials Used
- Aluminum alloy, polycarbonate ABS plastic, silicon
- Industry
- Automotive
Challenger Story
As Chrysler LLC prepared to unleash its new, limited-production Dodge Challenger, prototype plastic components loomed as a stumbling block to launch - until one rapid prototype shop stepped up to the challenge...
- Development Time
- Eight Weeks
- Processes Used
- CNC Machining, Injection Molding, Prototype Tooling, Laser Processing
- Materials Used
- Aluminum, Plastic, Polyurethane
- Industry
- Automotive
Refrigerator Door
A shift in consumer demand and a quick response by a major appliance maker presented a series of challenges for prototyping firm......
- Development Time
- Eight weeks
- Processes Used
- CNC Machining, Forming, Laser Processing, Stamping, Stereolithography
- Materials Used
- Sheet Metal, Stainless Steel, Plastic, Polystyrene Foam
- Industry
- Consumer Appliance
Mini Van Table
New seating plan option for the Chrysler 2008 Town & Country Minivan makes timely production launch thanks in part to diverse rapid prototyping disciplines...
- Development Time
- Two weeks
- Processes Used
- Casting, Injection Molding, Laser Cutting, Machining, Stamping, Welding
- Materials Used
- Aluminum, Plastic, Polypropylene, Steel
- Industry
- Automotive
Our Case Studies
Small Part, Big Challenges, Major Implications
- Development Time
- One Week
- Processes Used
- Injection molding, machining, reverse engineering, SLA
- Materials Used
- Aluminum, brass, plastic, stainless steel
- Industry
- Culinary
Small Part, Big Challenges, Major Implications
- Development Time
- Three and a half weeks
- Processes Used
- EDM tooling, injection molding, machining, mold design, stereolithography
- Materials Used
- Acrylic, plastic
- Industry
- Automotive
Ford Truck Dealer Display
- Development Time
- Five Weeks
- Processes Used
- Injection molding, prototype tooling, rapid prototyping, reverse engineering
- Materials Used
- Aluminum alloy, polycarbonate ABS plastic, silicon
- Industry
- Automotive
LED Lighting Fixtures
- Development Time
- Four Weeks
- Processes Used
- Casting, CNC machining, hydroforming, injection molding, laser cutting, machining, rapid prototyping, RIM tooling, stamping, welding
- Materials Used
- Aluminum, carbon steel
- Industry
- Commercial Lighting
Oil Flow Tester Application
- Development Time
- Three Weeks
- Processes Used
- Casting, CNC Machining, Injection Molding, Rapid Prototyping, stereolithography
- Materials Used
- Plastic, Silicon
- Industry
- Automotive
Refrigerator Door
- Development Time
- Eight Weeks
- Processes Used
- CNC Machining, Forming, Laser Processing, Stamping, Stereolithography
- Materials Used
- Sheet Metal, Stainless Steel, Plastic, Polystyrene Foam
- Industry
- Consumer Appliance
Ring For Charger Plate
- Development Time
- Two Weeks
- Processes Used
- CNC Machining, Electrostatic Painting, Laser Trimming, Rapid Prototyping, Stamping
- Materials Used
- Carbon Steel
- Industry
- Formal Dinnerware
Juilliard Facia Panels
- Development Time
- Three Weeks
- Processes Used
- CNC Machining, Molding, Prototype Tooling, Rapid Prototyping
- Materials Used
- Epoxy Adhesives, Polymer Concrete, Polyurethane Foam
- Industry
- Civil Engineering
Mini Van Table
- Development Time
- Two Weeks
- Processes Used
- Casting, Injection Molding, Laser Cutting, Machining, Stamping, Welding
- Materials Used
- Aluminum, Plastic, Polypropylene, Steel
- Industry
- Automotive
Challenger Story
- Development Time
- Eight Weeks
- Processes Used
- CNC Machining, Injection Molding, Prototype Tooling, Laser Processing
- Materials Used
- Aluminum, Plastic, Polyurethane
- Industry
- Automotive
Detroit Diesel
- Development Time
- Two Weeks
- Processes Used
- CNC Machining, Injection Molding, Laser Processing
- Materials Used
- Plastic, Rubber, Steel
- Industry
- Automotive
Frame Assembly
- Development Time
- Twelve–Fifteen Weeks
- Processes Used
- CNC machining, hydroforming, laser processing, stamping
- Materials Used
- Steel
- Industry
- Automotive
Reflex Lighting Lenses
- Development Time
- Six Weeks
- Processes Used
- Injection molding, electroforming, reflex tooling
- Materials Used
- Acrylic, polycarbonate
- Industry
- Automotive
Banana Box Container
- Development Time
- Three Weeks
- Processes Used
- Injection molding, prototype tooling
- Materials Used
- Plastic, polyurethane, silicone
- Industry
- Packaging
Slow Cooker Grill
- Development Time
- Three Weeks
- Processes Used
- Forming, laser processing, stamping
- Materials Used
- Aluminum, steel
- Industry
- Recreational Equipment
SUV Lighting Lens
- Development Time
- Six Weeks
- Processes Used
- Injection molding, laser processing stamping
- Materials Used
- Plastic, polycarbonate
- Industry
- Automotive
Tail Lamp Lens
- Development Time
- Four Weeks
- Processes Used
- Injection molding, prototype tooling
- Materials Used
- Acrylic, aluminum
- Industry
- Automotive
Racing Car Front Nosepiece
- Development Time
- Two Weeks
- Processes Used
- CNC machining, prototype tooling
- Materials Used
- Carbon composites, polyurethane
- Industry
- Automotive
Rear Fascia Substrate
- Development Time
- Four weeks (Three iterations)
- Processes Used
- Injection molding, laser cutting, prototype tooling
- Materials Used
- Plastic, polyurethane, silicone
- Industry
- Automotive
Automotive Rear Tail Lamp
- Development Time
- Eight weeks
- Processes Used
- CNC machining, injection molding, prototype tooling
- Materials Used
- Aluminum alloy, plastic
- Industry
- Automotive
Banjo Axle
- Development Time
- Ten weeks
- Processes Used
- Prototype tooling, stamping, lase cutting, machining, robotic welding
- Materials Used
- Basis and high strength steels
- Industry
- Automotive
Portable Grill
- Development Time
- Three weeks
- Processes Used
- Stamping, casting, silicone molds to urethane parts
- Materials Used
- Steel, aluminum, urethane
- Industry
- Recreational equipment
Automotive Rear Tail Lamp
- Development Time
- Six weeks
- Processes Used
- Prototype tooling, injection molding, plating
- Materials Used
- Acrylic, ABS/PC blend
- Industry
- Automotive
Dishwasher
- Development Time
- Three weeks
- Processes Used
- Stamping, assembly, laser cutting, spot welding, crimping
- Materials Used
- Stainless steel
- Industry
- Consumer appliance
Ergonomic Chair
- Development Time
- Three weeks
- Processes Used
- Casting, rapid prototype models, foundry tooling
- Materials Used
- Aluminum, iron, urethane
- Industry
- Office furniture
Automotive Headlamp
- Development Time
- 18 months; 20 design iterations; 50 components
- Processes Used
- Prototype tooling, injection molding, high-speed machining, assembly
- Materials Used
- Various
- Industry
- Automotive / Lighting
Engine Mount Bracket
- Development Time
- Three weeks
- Processes Used
- Prototype tooling, stamping, laser cutting
- Materials Used
- High-strength, low-alloy steel
- Industry
- Automotive
Engine Mount Bracket
- Development Time
- Three weeks
- Processes Used
- Stamping, forming, laser cut
- Materials Used
- High-strength, low-alloy steel
- Industry
- Automotive
Garden Tractor Fender
- Development Time
- Four weeks
- Processes Used
- Prototype tooling, stamping, laser cutting, extrusion
- Materials Used
- Mild steel
- Industry
- Consumer outdoor equipment
Solvent Vent Device
- Development Time
- Two weeks; three design iterations
- Processes Used
- Prototype tooling, injection molding
- Materials Used
- Polycarbonate
- Industry
- Scientific Equipment
Speaker Bracket
- Development Time
- Two weeks
- Processes Used
- Stamping, laser cutting, extrusion, plating
- Materials Used
- Mild steel
- Industry
- Automotive