3D printing — also called additive manufacturing — builds objects layer by layer from a digital model. Instead of cutting away material like CNC or shaping it with molds like injection molding, the printer adds material only where it's needed. That lets us turn a digital idea into a real part in hours, no tooling, no setup fees, no minimum runs.
How it works
We start with a digital 3D model — either designed in CAD or imported from a file the customer provides. Software slices that model into thin horizontal layers. The printer then builds the object one layer at a time, with each new layer fusing to the one below it.
Most of our work uses fused filament printing, where plastic filament is melted and extruded through a precise nozzle that traces each layer's shape. Depending on the part, finishing can involve removing supports, light sanding, or just pulling it off the bed and handing it over.
The material we run
For the type of items we produce, we prefer PLA (Polylactic Acid). It comes in a wide variety of colors and finishes, and our higher-end machines can print up to sixteen different colors on a single layer — so having materials with broad color and texture options matters to us. We also avoid frequent material changes because switching filaments can clog nozzles, so most of our printers stay set up for PLA.
We've also had good results with TPU (Thermoplastic Polyurethane). TPU is a flexible material available in different durometers, ranging from fairly stiff to almost rubber-like. It's become popular in footwear manufacturing, which has led to a big increase in available colors. That renewed variety has caught our attention again, so we may start running TPU more regularly.
What it's good at
- Design freedom. Complex geometries, internal channels, lattice structures, organic shapes — things that traditional manufacturing struggles with or can't do at all.
- Rapid prototyping. A design change in the morning can be a physical part to hold by the afternoon. Iteration cycles measured in hours, not weeks.
- No tooling cost. No molds, no dies, no machine setup. A single one-off costs about the same per unit as the tenth one.
- Less waste. Material gets added only where it's needed, instead of being cut away from a block.
- Customization without overhead. Every print can be a different design. That makes it great for personalized items, replacement parts, and one-off jobs.
Where it falls short
- Slow for high volume. Each part is built layer by layer, which makes 3D printing dramatically slower than injection molding or stamping when you need hundreds or thousands of identical pieces.
- Not the cheapest at scale. 3D printing is cost-effective for one-offs and small batches. Once you're past a few hundred identical parts, traditional manufacturing methods usually win on price.
- Material limits. Material options keep expanding, but traditional manufacturing still supports a broader range with proven mechanical properties. PLA isn't going to replace a forged steel bracket.
- Size limits. Most printers have a fixed build volume. Larger parts need to be designed as multiple pieces and joined.
- Some post-processing. Supports, light sanding, or surface finishing may be needed depending on the part.
Where 3D printing fits
3D printing is the right tool for prototypes, custom parts, small production runs, replacement pieces, jigs and fixtures, complex geometries, and items where the design is going to change. It's not the right tool for high-volume production, high-strength structural components, or applications that need certified materials.
For what we do here — short runs, custom work, things that need to exist tomorrow — 3D printing is one of the most useful tools in the shop.