3D printing project case studies.
ASTCAD’s 3D printing project case studies — rapid prototypes, end-use production parts, jigs and fixtures across FDM, SLA, SLS and metal DMLS technologies. From single prototypes to small-batch production for Australian manufacturers.
Featured 3D printing projects.
A selection of ASTCAD’s signature additive manufacturing projects — FDM, SLA, SLS and DMLS metal printing across aerospace, medical devices, mining equipment, marine and electronics manufacturing. From rapid prototyping to qualified end-use parts.
UAV airframe — 14 FDM iterations in 8 weeks
Carbon-fibre nylon airframes for flight testing. 1/15th the cost of traditional prototyping; transitioned to injection moulding.
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Medical therapy helmet — patient-specific SLA
CT-derived patient-specific geometry, SLA printed in biocompatible photopolymer. Supported TGA regulatory submission.
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Titanium aerospace bracket — DMLS
Topology-optimised Ti-6Al-4V bracket via DMLS — 47% mass reduction vs. billet machined, fully AS 9100D qualified.
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Industrial valve body — SLS production part
14-part machined assembly consolidated into a single SLS-printed body. 32% lower unit cost; zero leak failures in 18 months.
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Lithium battery enclosure — electric watercraft
Flame-retardant nylon enclosure in production for 6S battery pack — 60% lower unit cost vs. injection moulding at low volume.
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Production-floor jigs and fixtures — 38 units
38 custom production fixtures in 6 months. Lead time cut from 4 weeks to 3 days; 22% reduction in NPI cycle time.
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Multi-process 3D printing service offering
FDM, SLA, SLS and DMLS capability available through our partner network — from concept models to end-use production.
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Reverse engineering for 3D printing replacement parts
Legacy machine components 3D-scanned, redesigned and 3D-printed as direct replacement — keeping ageing equipment in service.
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Architectural concept models — SLA
High-detail SLA architectural massing models for client presentations and design competitions across multiple practices.
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