Our parts increase the flow of information by allowing journalists to access locations otherwise unnavigable with non-customized protective safety features.

Customer

• Specialty Vehicle Manufacturer for the Communications industry (Satellite Trucks).

Application

• Variability of end use production geometries via 3D Printing reducing tooling costs & lead times.

Challenge

• Manufacture 5 trucks for a customer order, each requiring a unique front bumper design for varying terrain in the mountains of Eastern Afghanistan.

Solution

• 3D print entire main section of a bumper in a single piece on PrintForm’s large frame SLA machines, hand finished, create a silicone mold and cast 5 copies in High Impact ABS Like Polyurethane material. 3D Print bottom skirts at varying heights for the specific truck’s needs according to assignment location’s terrain. Design mechanical interlocking features to permanently “snap” the SLS components into the bottom of the cast bumpers.

Benefit

• Transitioned from historically injection molded or CNC machined parts that took 6-8 weeks to build and at far more cost, to a customizable 3D printed pattern and silicone tool that is usable for up to 50 casts, each delivered in under a week. Combine multiple PrintForm processes to create a purpose-built manufacturing process utilizing 3D printing, cast urethane, and engineering expertise to deliver a near seamless end product for functional ‘in the field’ use.