Real orders, real constraints, real delivery dates. Customer names are withheld where confidentiality applies; the parts, processes and results are not.
Aluminium heat sink for a power electronics startup
Challenge
Fourteen fins inside a 60 mm envelope, mounting face flatness critical for thermal contact. Prototype needed within one week for a funding demo.
What we did
Printed in AlSi10Mg, machined the mounting face flat after printing, bead blasted the fin array. DFM review flagged two fins that were too thin at the root and were thickened before printing.
Result
Four units delivered in six working days, flatness verified on a CMM. The design later moved to extrusion for volume — we recommended the transition.
PA12-CF replacement gear for packaging machinery
Challenge
Original moulded gear obsolete, machine down, no drawing and no spare. Production line losing output every hour.
What we did
Reverse-engineered the worn part by measuring tooth profile and centre distance, modelled it, printed one test piece in PA12 and one in PA12-CF for comparison.
Result
Machine back in production in five days on the carbon fibre version. Two spares printed as buffer stock against future failure.
316L stainless manifold with internal channels
Challenge
Internal channel geometry could not be machined in one piece; the original design was a three-part weldment that leaked at the joints.
What we did
Printed as a single body, stress relieved, machined threads and sealing faces, then pressure tested at 1.5× working pressure.
Result
Three-piece welded assembly replaced by one printed part. Leak path eliminated and assembly time cut to a single operation.
Small-batch enclosure run in SLA resin
Challenge
Fifty units needed for field trials before injection mould tooling was justified. Cosmetic surfaces had to look production-grade.
What we did
Printed in tough resin, sanded and primed, then painted to the customer's colour reference. Threaded inserts installed by hand.
Result
Fifty units in twelve working days. Tooling decision deferred until field data was in — the customer avoided a five-figure mould spend on an unvalidated design.
Note for the site owner: replace these four cases with your own projects before going live. Keep the structure — challenge, what we did, result — and keep every number true. Do not publish customer names without written permission.