Automotive
Challenge
McLaren Racing relies on composite materials for aerodynamic race car components, as they offer an ideal balance of strength and weight. However, producing new composite parts requires tooling fabrication and lengthy curing processes, making it difficult to respond quickly when design changes are needed.
Solution
To accelerate production without compromising performance, McLaren turned to 3D printing with FDM Nylon 12CF. Reinforced with chopped carbon fiber, the material delivers the strength and stiffness required for demanding motorsport applications, while eliminating the need for traditional tooling.
Impact
McLaren reduced the time required to produce functional parts from 29 days to just five days and lowered costs by ~25%. Now, the team can replace critical components in time for upcoming races, improving both performance and operational efficiency.
Aerospace & Defense
Challenge
The U.S. Air Force lavatory components on the C-17 aircraft operate in harsh chemical environments and require dependable sealing performance. Traditional replacement methods often result in high costs, long lead times, and extended aircraft downtime.
Solution
The Pittsburgh Air Reserve Station and Travis Air Force Base implemented a structured additive manufacturing workflow using the F900. Teams progressed from ASA prototypes to ULTEM™ 9085 qualification parts before producing final components in Antero 800NA to achieve the required chemical resistance and performance.
Impact
The cost of a replacement drip pan was reduced from approximately $10,000 to $1,200, representing an 88% savings. Lead times dropped from weeks to less than 60 hours, establishing a repeatable pathway for qualified, on-demand replacement parts. Unable to source the original component, the team reverse-engineered the toilet base to develop validated replacement parts for future use. With REDI-approval in place and installation tracking maintained on a per-aircraft basis, the Air Force now has a governed mechanism to scale adoption. The success of the program has since expanded to 12 C-17 components produced on the F900.
Anatomical Models
Challenge
The Florida Pediatric Hospital sought a more effective way to improve surgical planning, physician training, and patient care through highly realistic anatomical models. When rare surgical cases would arise, surgeons had limited time and resources to figure out the best way to operate on the patient. Without access to patient-specific anatomical models, it was difficult to predict a successful outcome.
Solution
Using the J850 Digital Anatomy Printer, the hospital produced patient-specific models that accurately replicate the appearance and feel of human anatomy. Advanced materials such as TissueMatrix, BoneMatrix, and GelMatrix enabled the creation of highly detailed models for physician training, surgical simulation, and procedural planning.
Impact
Surgeons can now rehearse procedures before entering the operating room, ensuring patient confidence and helping reduce surgical time, anesthesia exposure, and potential complications. The ability to produce realistic training models has also strengthened the hospital’s educational programs, delivering significant value for physician training and clinical preparation.
Industrial Production
Challenge
A late-stage design change to the front grill camera mount on the Roush F-150 threatened production schedules. Creating new injection mold tooling would have added significant cost and delayed vehicle delivery.
Solution
Rather than redesigning tooling, Roush produced the mounts using SAF technology on the H350. The process delivered the consistency, accuracy, and mechanical performance necessary to meet PPAP requirements, as well as enabled rapid design validation and production.
Impact
By switching to additive manufacturing, Roush reduced production cycle time by more than 50% and achieved approximately 35% cost savings compared to an injection-molded solution. 3D printing also revealed opportunities to improve the design before production, preventing additional tooling costs and further delays.
Dental Dentures
Challenge
Posca Brothers Dental Laboratory wanted to differentiate itself from competitors, increase production capacity, and provide more realistic, aesthetically pleasing dental appliances.
Solution
The lab adopted TrueDent and the J5 DentaJet to produce monolithic, full-color dentures and removable partial dentures – all in a single print. This digital workflow eliminates manual tooth bonding and enables simultaneous production of multiple shade combinations on a single build tray.
Impact
The lab now produces up to 34 full-color dentures in a single build, increasing production capacity by 10X and significantly reducing labor requirements. Dentists report excellent fit, comfort, and aesthetics, and patients benefit from highly accurate restorations that can be easily reproduced whenever needed.
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