Portfolio & Case Studies
Real projects from Charlotte-area businesses. See how 3D printing solves manufacturing challenges, accelerates product development, and reduces costs.
Manufacturing Fixtures for Lake Norman Production Facility
ManufacturingChallenge
A Lake Norman electronics manufacturer was experiencing a 3% defect rate during PCB assembly due to hand-positioned components. Machined fixtures quoted at $1,200 each with a 3-week lead time.
Solution
We designed and 3D printed custom nest fixtures in PETG that held all components in precise alignment during soldering. Each fixture was iterated on-site until the fit was perfect.
Result
Defect rate dropped from 3% to 0.3%. Cycle time reduced by 22%. Each fixture cost $85 — 93% less than the machined alternative.
Rapid Prototyping for Charlotte Startup Product Launch
PrototypingChallenge
A Charlotte consumer electronics startup had spent 6 weeks going back and forth with an overseas prototyping vendor. Their enclosure prototype didn't fit the PCB, and each revision took 10-14 days.
Solution
We printed the first revised prototype within 3 days. After an in-person fit check at our Charlotte facility, we identified two modifications and had the final version ready 48 hours later.
Result
Total time from first contact to approved prototype: 7 days — compared to the 6+ weeks already spent. The startup hit their product launch deadline.
Custom Enclosures for Electronics Company
ProductionChallenge
An electronics company needed weatherproof enclosures for outdoor sensor units. Injection molding was cost-prohibitive for their initial run of 200 units, and off-the-shelf enclosures didn't fit their custom PCB layout.
Solution
We designed custom enclosures in ASA (UV-stable) with integrated mounting points, cable glands, and snap-fit lids. The design went through 3 rapid iterations before production.
Result
200 enclosures delivered in 2 weeks at 60% less than the injection molding quote. The snap-fit design eliminated the need for fasteners, reducing assembly time by 40%.
Architectural Scale Model for Charlotte Development
ArchitectureChallenge
A Charlotte architecture firm needed a detailed scale model of a mixed-use development project for a city planning presentation. Traditional model-making would take 3-4 weeks.
Solution
We 3D printed the building components in white PLA at 1:200 scale, with separate pieces for each building phase. The modular design allowed the client to show the project in stages during their presentation.
Result
Complete model delivered in 8 days. The modular approach was a hit with the planning committee, and the firm has since ordered models for three additional projects.
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