3D Printing Portfolio | Production Parts and Prototypes

Challenge: The client needed custom drone mounts and airframe components for crop spray and mapping platforms. Off the shelf parts could not withstand field conditions including UV exposure, moisture, and constant vibration. They needed 50 units for initial field testing.

Solution: Spline Arc reverse engineered the mounting geometry from existing samples and printed 50 units in ASA, a UV resistant material ideal for outdoor agricultural use. Tolerances were held within 0.2mm across all units to ensure consistent fit on the UAV platform.

Result: All 50 units passed field testing. The client placed a follow on order of 200 units for full fleet deployment. Parts showed no degradation after 3 months of daily UV and moisture exposure.

Challenge: The client had a functional prototype of a new consumer device but needed 100 units for a market validation pilot run before committing to injection molding tooling. They needed the pilot units to look and feel like production parts for stakeholder demonstrations and user testing.

Solution: Spline Arc printed 100 enclosure shells in PETG with vapor smoothing post processing to achieve a production like surface finish. Internal mounting bosses and cable management features were printed to tight tolerances to ensure PCB and component fit. Each unit was inspected and packaged for direct to customer shipment.

Result: The pilot run generated $47,000 in pre orders. The client used feedback from the 100 unit run to refine the design before committing to injection molding. Spline Arc now serves as their bridge production partner for ongoing demand between tooling cycles.