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Case studies

Real engineering problems. Predictable outcomes.

The examples below highlight how we support engineering teams with functional prototypes, fixtures, and low-volume production parts. Customer names are withheld to protect confidentiality.

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Manufacturing Fixture & Tooling

Assembly fixture for repeatable alignment

A manufacturing team needed a fixture to align and hold parts during a repetitive assembly operation. Previous hand alignment caused variability and rework.

  • Challenge: Improve repeatability without long machine-shop lead times
  • Solution: Engineer-reviewed fixture with stiffness-driven material selection
  • Material: Nylon-based engineering polymer
  • Lead time: 3 business days
  • Result: Reduced assembly variation and faster throughput
Aerospace Support Prototype

Fit-check prototype for constrained installation

An aerospace engineering team required a prototype to verify fit and clearance inside a tightly constrained assembly before committing to production tooling.

  • Challenge: Validate fit without risking late design changes
  • Solution: Orientation-optimized prototype with controlled tolerances
  • Material: PETG
  • Lead time: 2 business days
  • Result: Early design issue identified and corrected before release
Medical Devices Prototype

Ergonomic housing prototype for usability testing

A medical device startup needed multiple housing iterations to evaluate ergonomics and user interaction during early-stage development.

  • Challenge: Rapid iteration without losing dimensional consistency
  • Solution: Revision-aware builds with consistent orientation and parameters
  • Material: ABS / ASA
  • Lead time: 2–3 business days per iteration
  • Result: Faster design convergence with fewer reprints
Oil & Gas Functional Part

Durable housing for harsh environment testing

An engineering team required a rugged prototype housing to support testing in a harsh, industrial environment with repeated handling.

  • Challenge: Balance durability with rapid turnaround
  • Solution: Thick-walled design with impact-aware orientation
  • Material: Glass-filled polymer
  • Lead time: 4 business days
  • Result: Successful testing without part failure
Advanced R&D Low-Volume Production

Revision-controlled batch for pilot builds

A research team needed a short-run batch of functional parts for pilot testing. Consistency across units and revision control were critical.

  • Challenge: Maintain consistency across a small production run
  • Solution: Controlled parameters with documented build settings
  • Material: Engineering-grade polymer
  • Quantity: 25 units
  • Result: Uniform parts delivered on schedule with no rework

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