Parts we have made, and what they had to solve.

Six projects across aerospace, medical, building services and the factory floor. Every one lists the process, the material and the time it actually took.

Industrial machinery

Pneumatic manifold with conformal channels

Nine machined blocks and their fittings consolidated into a single printed manifold.

The problem

The original assembly was nine machined blocks bolted together, with twenty-two sealing faces that each represented a possible leak. Drilled straight channels forced sharp turns in the flow path and cost pressure at every corner.

What we did

Printing let the channels curve the way the air wants to travel. The part came out 38 % lighter, dropped less pressure across the circuit, and removed every one of the twenty-two seals.

Client
Agricultural equipment manufacturer
Process
SLS
Material
Glass-filled PA12
Quantity
40 units
Delivered in
11 days

Medical devices

Sealed enclosure for a portable diagnostic unit

A pre-production run in the hands of clinical testers eight weeks before tooling was ready.

The problem

The team needed enclosures good enough for a clinical trial, but injection tooling was three months out and the housing was still changing between revisions.

What we did

Printed housings with moulded-in gaskets and heat-staked inserts passed the IP54 test. Two design revisions went through mid-run, which tooling could never have absorbed.

Client
Medical device start-up
Process
SLA
Material
Tough 2000 resin, painted
Quantity
120 units
Delivered in
9 days

Aerospace

Flame-retardant cable duct for a cabin retrofit

A fire-certified duct for a retrofit too small to justify tooling.

The problem

The retrofit covered twelve aircraft. Dedicated tooling would never have paid for itself at that volume, and the cable route had to clear structure that varied slightly between airframes.

What we did

Printed in flame-retardant PEI, the duct passed cabin interior flammability testing on the first attempt. Each unit was fitted to its specific airframe at no tooling cost.

Client
Aircraft interiors integrator
Process
FDM
Material
Flame-retardant PEI (ULTEM 9085)
Quantity
8 units
Delivered in
18 days

Architecture

Lattice diffuser for a cleanroom ceiling

A gyroid lattice that spreads airflow evenly without the noise of a perforated plate.

The problem

Perforated diffusers whistled at the required air-change rate and produced draughts directly under each panel, which the validation protocol would not accept.

What we did

A gyroid lattice, impossible to mould and impractical to machine, dropped measured noise by 9 dB and flattened the velocity profile across the ceiling.

Client
Laboratory fit-out contractor
Process
SLS
Material
PA12 nylon
Quantity
260 units
Delivered in
14 days

Reverse engineering

Replacement impeller for a discontinued ventilation unit

A worn impeller with no drawings and no supplier, scanned and rebuilt.

The problem

The unit manufacturer had closed in 2004. The only reference was the worn impeller still in the housing, and replacing the whole air handling unit meant a six-figure capital request.

What we did

We scanned the worn part, rebuilt the blade profile to its as-designed geometry, and printed three in PA12. Measured flow came back 4 % above the original nameplate.

Client
Hospital facilities manager
Process
SLS
Material
PA12 nylon
Quantity
3 units
Delivered in
21 days

Production tooling

Go/no-go gauge set for a weld line

A full set of shop-floor inspection gauges delivered inside a week.

The problem

A new model year changed eighteen weld positions. Machining a matching gauge set quoted at seven weeks, which was three weeks past the line changeover date.

What we did

Printed glass-filled gauges shipped in six days at a third of the machining cost. Wear checks after nine months of shift use show them still inside tolerance.

Client
Automotive tier-two supplier
Process
MJF
Material
Glass-filled PA12
Quantity
54 units
Delivered in
6 days

Your part could be the next one here.

Most of these started as one email with a file attached and a question about whether it could be printed at all.

Request a quote