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Real Projects, Proven Results

From emergency medical device repairs to vintage automotive restoration, see how flexible manufacturing solves real-world problems.

127
Projects Completed
2024
4.2 days
Average Turnaround
Design to Delivery
78%
Client Retention Rate
12-month
94%
First-Time Success Rate
No Iteration Required
Case Study #1 SLA

E30 BMW Door Seal Restoration

Client: Classic BMW Enthusiast Community

Challenge

Original seals discontinued in 2019, aftermarket alternatives too rigid

Solution

Reverse-engineered using 3D scanning, printed in Shore 80A flex resin

Timeline: 5 days from sample to delivery
Volume: 47 units across 12 vehicles

Key Results

  • ✓ Perfect fitment on first iteration
  • ✓ 15% cost savings vs. NOS parts
  • ✓ Generated 23 referrals within 60 days
"Finally found someone who actually understands these cars. The seals feel exactly like original equipment."

Project Metrics

customer Satisfaction 98%
repeat Orders 34%
revenue Per Unit $87

Process Workflow

  1. 1 Initial consultation & requirements gathering
  2. 2 3D scanning or reverse engineering
  3. 3 Material selection & test printing
  4. 4 Production run & quality control
  5. 5 Delivery & installation support
Case Study #2 FDM (TPU)

Williams Pinball Flipper Rebuilds

Client: Vintage Arcade Restoration Shop

Challenge

Flipper rubber degraded, causing inconsistent ball response

Solution

Custom durometer matching using material sample deck

Timeline: 2 weeks for testing, 1 day for production run
Volume: 150 pieces for 8 machines

Key Results

  • ✓ Improved ball response consistency by 40%
  • ✓ Reduced flipper maintenance from monthly to quarterly
  • ✓ Client expanded to order bumper sets
"These perform better than the original rubber ever did. Our tournament players notice the difference immediately."

Project Metrics

customer Satisfaction 96%
repeat Orders 67%
revenue Per Unit $12

Process Workflow

  1. 1 Initial consultation & requirements gathering
  2. 2 3D scanning or reverse engineering
  3. 3 Material selection & test printing
  4. 4 Production run & quality control
  5. 5 Delivery & installation support
Case Study #3 SLA

Medical Device Gasket Emergency

Client: Hospital Equipment Maintenance

Challenge

Critical gasket failure on weekend, 48-hour patient procedure deadline

Solution

Emergency response protocol with same-day measurement and overnight print

Timeline: 36 hours total turnaround
Volume: 3 units (with 5 spares)

Key Results

  • ✓ Procedure completed on schedule
  • ✓ Established ongoing maintenance partnership
  • ✓ Created digital inventory for future needs
"This level of responsiveness saved our patient's procedure. Now we keep digital files for all critical gaskets."

Project Metrics

customer Satisfaction 100%
repeat Orders 89%
revenue Per Unit $245

Process Workflow

  1. 1 Initial consultation & requirements gathering
  2. 2 3D scanning or reverse engineering
  3. 3 Material selection & test printing
  4. 4 Production run & quality control
  5. 5 Delivery & installation support

Ready to Start Your Project?

Whether it's an emergency replacement or a planned restoration, we're here to help bring your parts back to life.

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