Manufacturing Capabilities for Complex Geometries, Functional Parts & Production

DMLS ensures the accurate repeatability of quality metal 3D printed parts. The process allows for greater design flexibility, and no tooling or fixturing means we can print multiple parts with minor design changes between builds.

DMLS metal printing is a powder-bed process that uses microwelding to fuse material together. It excels at heat exchangers, conformal-cooling injection mold inserts, drill bits, casting replacement, and other functional metal parts. Our team has been printing metal on DMLS machines since 2004, and our growing fleet lets us react quickly to larger projects.

Best For

Functional metal parts, conformal cooling, heat exchangers, casting replacement.

Materials

Titanium, Aluminum, Inconel, Tool Steel, Stainless Steel, and more.

Tolerance

As tight as +/- 0.005" (0.13 mm) depending on geometry and post-processing.

Build / Run

Multiple platforms; expanding fleet for larger projects.

FDM, also known as Fused Filament Fabrication, uses thermoplastic polymer filaments to build parts layer by layer along a predetermined path. Industrial-grade equipment lets our teams print larger models, hold tighter tolerances, and produce single-piece parts without reassembly.

Assembly fixtures, rapid tooling, brake-press tooling, rapid thermoforming tools, drill masks, metal-forming tooling, and functional plastic parts are just a few applications. We print in everything from ABS to Ultem, with our Fortus 900 machines providing a 24" x 36" x 36" (610 x 914 x 914 mm) build volume.

Best For

Tooling, fixtures, jigs, drill masks, and large functional polymer parts.

Materials

ABS, ASA, PC, PC-ABS, ESD-safe grades, Nylon 12, Ultem 9085, Ultem 1010, and more.

Tolerance

Industrial machines hold tight, repeatable tolerances over large geometries.

Build / Run

Up to 24" x 36" x 36" (610 x 914 x 914 mm) on Fortus 900.

A true thermoplastic and a popular choice among engineers and manufacturers, SLS is a strong fit for low-volume production with ROI/break-even paybacks that beat injection molding. Many racing teams, including Formula 1, turn to SLS for strong functional parts with quick iteration for wind-tunnel testing.

Our experts use SLS for rapid prototyping, product mockups, functional prototyping, end-use part production, stop-gap manufacturing, and models. Typically nylon-based, we offer glass-filled and non-glass-filled materials to rapidly grow your future injection-molded component or support low-volume production.

Best For

Functional nylon parts, low-volume production, and bridge tooling.

Materials

Glass-filled Nylon 12 standard; unfilled PA12, carbon-filled nylon, and TPU 88A by request.

Tolerance

Production-grade repeatability suitable for fit and function.

Build / Run

Multiple platforms scaled for prototype through bridge production.

Digital Sheet Metal Forming is the latest advancement in our field. By eliminating expensive die manufacturing, DSMF lets us create sheet metal parts in minutes and hours instead of days and weeks, which saves both time and money.

Single-point forming creates the intricate contours common in automotive, aerospace, and industrial parts. The process holds the accuracy and repeatability to handle complex shapes that used to require hard tooling.

Best For

Complex sheet metal contours, small-to-medium batches, and rapid prototyping without hard tooling.

Materials

Aluminum, steel, stainless, and other formable sheet metals.

Tolerance

Precise, repeatable forming controlled point by point.

Build / Run

Single parts through small and medium production batches.

PolyJet jets photopolymer droplets and cures them with UV light, building detailed parts and prototypes in hours. The process holds fine features and produces smooth surfaces straight off the machine.

It works well for multi-color parts and accurate assembly models. We have also printed silicone molds from this process for gaskets and other infusion parts.

Best For

Multi-material and multi-color models, detailed prototypes, and silicone tooling masters.

Materials

Rigid, flexible, transparent, and multi-color photopolymers.

Tolerance

Industry-leading accuracy and surface finish.

Build / Run

Production-grade build envelopes for assemblies and presentation models.

Cold spray builds metal parts by accelerating powder particles to supersonic speeds so they bond on impact, without melting. Because the process stays well below the melting point, parts avoid the heat distortion and residual stress that come with fusion-based metal printing.

Through our partnership with Titomic, we run Titomic Kinetic Fusion to produce large-format metal parts, apply protective coatings, and repair high-value components. It pairs well with Digital Sheet Metal Forming when a project needs near-net metal shapes at scale.

Best For

Large-format metal parts, coatings, and repair of high-value components.

Materials

Titanium, copper, aluminum, nickel alloys, and bi-metallic combinations.

Tolerance

Near-net shapes finished to print with secondary machining.

Build / Run

Large build envelope suited to oversized metal geometries.

SLA, also known as resin 3D printing, selectively cures polymer resin layer by layer using an ultraviolet laser. Our SLA capabilities deliver very high dimensional accuracy and intricate features, with smooth surface finishes ideal for visual prototypes and detailed assembly models.

We typically print the majority of our SLA parts in clear material to visualize interference fits in complex injection-molded assemblies and to simulate lenses for lighting fixtures.

Best For

High-detail visual prototypes, fit-and-finish models, and clear lens simulations.

Materials

Standard resins, clear, tough, and high-temp options.

Tolerance

Very high dimensional accuracy with smooth surface finish.

Build / Run

Multiple build envelopes for small to medium parts.