Haddington Dynamics started out with a Kickstarter for a DIY advanced collaborative robot called Dexter. The arm used a new type of control chip and advanced dynamics to attain very high precision at a very low cost.

The Kickstarter was successful with Haddington gaining $108,000 dollars in preorders. But there was a problem. They did not have the capacity to fulfill them. So they reached out to Slant 3D in 2017 and our large scale 3D Printing farms. So started a long relationship. Slant 3D ended up producing thousands of parts for Haddington that met the quality and scale that they needed as they grew. And along the way they transitioned from standard plastic components to Carbon Fiber Re-enforced parts.

​Today we are very happy to see Haddington hit a new milestone by being purchased by British online supermarket Ocado. Haddington's technology will be deployed as a way to help with warehouse management and distribution. 

Haddington was purchased for 25 million dollars in cash and stock and can look forward to having their 3D Printed robot arms helping to delivery groceries to thousands of happy customers.

Mass Production 3D Printing is a very affordable means of producing custom shipping trays and packaging. Since there is no molding cost, but a still a high production capacity, custom packaging solutions can be created for the same of less cost as traditional methods. And, and since it is always a custom solution the results are often better.

3D Printing can quickly create custom trays at volume without a long lead time or high expense. Generally it takes about a 1-2 weeks to complete production of several hundred trays. And depending on material the cost per chip for the packaging can be between $0.10 and $0.50, comparable to traditional solutions.

But since 3D Printing is a different process these trays need to be designed slightly differently. Here are some basic notes for your internal design teams if they are looking to design custom PCB trays. Though we also offer Design services if needed

Traditional designs would just have a peg with a hole to act as a finding feature when trays are stacked. This does not work with 3D Printed PCB trays because that would create an overhangin during printing. And overhang is a feature that juts at 90 degrees from a part, like the branch of a tree. Most trays are printed on end so finding pegs become that overhang.

The other option that perfectly replaced the peg is a slot and tab. Just make certain to have the the them positioned parallel to the longest side of the tray (Again because the part will be printed with its longest side vertical on the print bed.)

FDM 3D Printing is used to create these types of trays therefore there is a limit to how large of an bridging overhand, like the top of a chip slot, can be. generally if that upper surface is greater than 1 inch wide then this option needs to be used.

Basically, the rotate chip slots so that they no longer follow a rectangular pattern. Instead of squares they become diamonds. This eliminates the overhang and instead gives each slot a slanted roof.

This is a very simple rule. But it provides a huge advantage because it can reduce cost and improve quality at the same time. Just eliminate any sharp edge, and if a fillet can be made larger, make it larger.

While 3D Printing requires some shifts in design thinking due to manufacturing limitations, there are a few things that it contributes that can vastly improve your product. Since there is no mold involved you can actually create features for free that were not even possible before. Labeling is one of those.

This labeling can be something as simple as the name of the company producing the chips, or information about the batch and chip name for us in production. An example of branding is shown below for one of our clients Silicon Mountain Contract Services

Not many trays are able to actually retain the chip in place so that it won't fall out. These features are exceptionally difficult to mold affordably.  But with 3D Printing they are free to add.

Production 3D Printing can create exceptionally complex mechanisms, again without significant added cost depending on the cost. But for specialty applications systems can be created that control chips in just the right way so that they are not damaged but are released when needed in a production line. When working with Plexus we created a simple locking tab system that was able to hold the proprietary chips from the side but them lock open so that they could be removed on the factory floor.

3D Printing is very affordable and very flexible, it is an ideal way to create custom packaging solutions for PCB's or any other type of product. Why we have even done consumer packaging at times.

But the quickest way to find out if 3D Printing is right for your application is to submit a quote with your needs and specifications and one of our account engineers will be in contact with you soon.

So how is a final product manufactured with mass production 3D Printing? And more importantly what is the development process leading up to final production.

Well, there are a few steps. Mainly there to ensure that the final product is within spec for the client. Mass Production 3D Printing offers much more control and variation than traditional processes. And since it is relatively new there are areas that we think it is important that a client understand early on which can reduce cost and provide amazing new opportunities if utilized.

With this post we hope to outline the general process and why it exists, and give mass production 3D Printing clients a "look behind the curtain"

If the title is not clear enough this post focuses only on the process of mass production 3D Printing. Which is generally longer and more intensive than prototyping 3D printing. If you just need a part made quickly for testing we recommend going to our prototyping service Twist 3D Printing

This sounds simple but can be confusing, mainly because there are dozens of 3D model formats. And what is submitted might have limitations.

When we request a 3D model we prefer a .STEP, .STL, the original CAD, or a .OBJ file. And if you are sending a zip a dimensioned drawing with critical tolerances is nice icing on the cake.

 A .STEP file is the strongest because it is immediately editable, and contains accurate dimensional information. It is pretty much the universal 3D model file. And the editability is also great because we can quickly implement slight modifications that do not change the function of the part but improve its manufacturability.

Original CAD files can be converted but not always, and they can delay processing of quotes.

.STL and .OBJ are often submitted by clients with a history in 3D printing. And these files are fine. But they have no universal units associated with them and can therefore be incorrectly scaled during processing. And since they are generally files that have been developed for 3D Printing they are generally focused toward the machine or process that they were prototyped on. Which means that tolerances may be off for the mass production 3D Printing method. And last of all they are uneditable. So these standard 3D printing files are the easiest to work with but can lead to many problems.

The need for a dimensioned drawings ensures that critical features are highlighted and the tolerances associated with them. This helps during the design review.

Overall, if you can send one of each file type that is great. If you submit a .STL make sure you provide the dimensions it was created it. Or just submit a .STEP file. If you have all the files to submit place them in a zip file.

If you have none of the files requested. Send what you have and we will work through it. But do expect a delayed processing

This is not uncommon. But a 3D model is required in order to 3D print the product so one must be created. Fortunately we offer a 3D modeling and engineering service, so we can create your model for you. Our team can create anything from engineering models to creative character modeling.

3D Modeling is billing at an hourly engineering rate. The advantage of our team is that they are able to optimize your part for mass production 3D Printing, speeding up the process down the line. 

If you are still indeterminant about what the final production process will be, then we do recommend hiring an independent design firm. Because our team's expertise is focused on 3D Printing, therefore should that not be the ideal avenue we might not have "all the tricks" for converting your model over to something like an injection molded format optimally. We are specialists and not explicitly a design firm.

When submitting a part there is always an option to "elaborate" on it its function and specs. While it is optional, due to confidentiality reasons, we highly encourage completing it for engineering and economic reasons. The more we know about your product and what it needs to do to function, the more we can help by offering advice about optimization and good design for additive manufacturing so you get the most bang for your buck.

Any file submitted to Slant 3D is kept confidential and will not be shared outside of the organization. Any employee of the company is required to sign an Non-disclosure agreement upon hiring covrting all projects within the company that they may interact with.

That company NDA is enforced upon all employees. But we will also sign NDA's put forward by clients. If you would like to have a 3rd party NDA signed before submitting files please either contact us first or send your NDA to info@slant3d.com

Once a file is submitted to use it is forwarded one of our design engineers. These people have some of the most in depth knowledge of mass production 3D Printing in the industry. We know this because Slant 3D operates the largest 3D Printing farms in North America. Once assigned the design engineer will be with your from the beginning to the end of your project and they will be the main point of contact.

The first thing that engineer does is quote your part. This will include slicing it and receiving estimates of material use and print time. The engineer will then use their expertise to optimize the process as much as possible at this stage and give a reasonable estimate.

The design and features are then fed to our quoting system which takes into account dozens of features about the part including capacity available, lead time, rejection rate, and of course material and print time to create a final estimate.

But we do want to emphasize that we do not always agree with the final quoting system. Design of a product and the optimization of it is a process that is so broad that there can be exceptions that our automated system can't deal with. That is why the design engineer is there, and we don't use a fully automatic quoting system. A good engineer can spot things that a computer can miss. And that leads to our next component

While the engineer and system are restricted to your design when quoting they will make design suggestions when the quote is delivered. 3D Printing is a new and often foreign process so we want to make sure that clients are able to utilize our expertise in the field to get the best result. There is no reason to hire a service if that service cannot lead to a more optimal solution.

So the engineer will offer modifications that can improve price, functionality, appearance, and manufacturability. These might be as simple as reminding a client that the best way to design for FDM production is to "Minimize surface area and don't worry about volume," an idea that is counterintuitive to those with a history in injection molding, to more detailed ideas such as adding specific features. The design engineer will also have the expertise to implement those design changes if necessary.

But this part is why it is so important to provide as much information about the function and critical features of the parts at submission. Without that information the engineer is not able to make optimal suggestions quickly. It is entirely possible that they could suggest something as simple as a different material to dramatically improve the economics. But if they don't know the function of the part then they must defer to the client entirely. Because the last thing we want to do it slow the process by changing your product. But we do think it is important to make our expertise available in every way possible.

When the quote and design review are sent over to you that is the first step of what will likely be an iterative process. Ideally the client will be able to implement any design notes that the design engineer offered and have the parts requoted. 

Sampling is part of the process that we consider very necessary in order to ensure that reality match expectations. Again mass production 3D Printing is quite new and we want to be certain that client are getting what they want.

A roughcut sample is a piece that has not been optimized for production. That means that it is not final and is not representative of the final product.

So why do them? Well we use roughcut samples as a quick and often free way to illustrate a challenge with the part that the client should be made aware of. For example, it may show how support material could be converted into a functional feature of the part with a redesign.

Though we are often hesitant to create roughcut samples, because clients often misconstrue them as representative of the final product, and they are not meant to be. For example, while highlighting a feature like support material usage a roughcut sample might be made with a large layer height for the sake of speed. But the client might assume that the large layer height is somehow part of the final product as well, which it most certainly isn't. So we are cautious because these quick and dirty pieces can create confusion.

Shipping Time  and cost can delay a project. And often mass production 3D Printing is used to shore up a leak in the manufacturing a supply chain. Much like in the beginning of the covid-19 pandemic. So to expedite this we can do photo samples.

These pieces are production ready prints of the part which are photographed in our studio to highlight every critical feature of the part. Some include caliper measures and color comparisons.

While not the same as holding a part these samples are quite common and can create some ease of mind when a part is ordered in a rush.

Of course we do these. But we call them a production prototype. Therefore a fee is applied that is a prototyping fee. At this stage we go though the full optimization process. It might include several iterations on the part finding the optimal process and tweaking tolerances. This is not a push-button part of the process. Therefore it can be quite expensive. While 3D Printing is most certainly more flexible than injection molding it is incorrect to assume that there is not still a setup process for a new part or product to make it just right.

The cost of a sample is the standard setup fee, plus shipping, plus the cost of the prototype of that part at the prototype quantity. Often these will be included in the first quote you receive.

There is a lot of possible variation in 3D Printing. There are different processes and an infinite control of part material behavior. Depending on application there is also a broad variation of requirement from clients. A bracket might not need to look good, but a vase must be immaculate. But those words are not quantifiable. Many clients will use "good surface finish," but that phrase can have wildly different interpretations based on their backgrounds.

Therefore we have adopted the "Eye Doctor" QC method during sampling. In most cases with new clients we will send multiple iterations of the same part to the client for them to evaluate. Some will be blatantly bad, some will be "immaculate." (Particularly in the area of appearance, tolerances after all are very cut and dry. "Look good" doesn't mean anything to an engineer.) When the client receives these samples we will use their feedback to establish a QC checklist that will be used during post processing in production to verify that parts are up to spec during production. This checklist might evolve and become more narrow overtime. 

Unfortunately there are not currently universal engineering standards within the additive manufacturing sector. So this has been the best method we have to ensure that we meet the clients standards when each client is different, and the technology is incompletely understood or designed for.

The quickest way to create a sample is to print it yourself and iterate until your have what you want. That eliminates shipping, and Slant 3D providing iterations to choose from. It can also be very fast since shipping and communication lags are eliminated. The reason it is not general practice is because no 3D Printer or process is created equal. And there are costs in the machine itself as well as skill of operation. We have years of experience, your company may only use it causally.

But we have fixed this problem with our Mason 3D Printer. The Mason is a prototyping machine. But one that leads directly to production with no intermediate steps. Anything made on a Mason is identical to what will come out of our 3D Printing farms. This dramatically speeds up sampling because the client can do it themselves. And if they do not have expertise in a particular area your design engineer can prepare an iteration of the part and email it you to print on your Mason. So you get our experience and one of our machines to work with in your facility or business.

Our clients who use this model often have many products (such as in a toy company) or designs which change dynamically (such as factory tooling).

As we have said the creation of the production sample is an iterative process. There is experimentation that can reveal problems with the piece that were overlooked during the digital quoting and evaluation process. Therefore after a production sample is made and evaluated the quote made need to be adjusted, either from features we find or from client feedback. 

Very often the design itself will change after samples are created. And every time the design changes the quote must be updated as well.

So the part has been submitted, the design has been optimized. The Sample has been approved. Now we are ready to actually make thousands of parts and really utilize mass production 3D Printing.

The payment method and structure will be decided during the quoting process. Generally it is quoted as payment upon order if the order is under a certain dollar amount. But that is flexible based on size of the order and the structure of the contract. 50% down and Net30 are common.

Note: The setup fees are applied anytime a design is changed or a production context changes. So the setup fee is billed at sampling and at production.

Not much to say here. We make the number of parts requested with the same specs as the approved samples. We do this by using fleets of 3D Printers.

Shipping can be done a number of ways. The most common are shipping in batches, just in time, and bulk shipping.

Batches are generally the fastest way to get parts, but can increase shipping costs. But this method can allow for the payment on delivery contract that spreads out expense over a longer period of time and allows for tighter control and iteration in between shipments. Remember 3D Printing allows for a design to be changed during production without a big uproar, just a refreshed setup fee.

Just in Time is often partnered with Slant 3D's fulfillment capabilities. When an order is made we are notified though a number of means and the part is printed and shipped. This can also include warehousing of inventory or just digital inventory. This is optimal for spare parts and high margin businesses where the cost of the single part can be higher.

Bulk Shipping, is just like injection molding. We make 100,000 parts and send them to you on a pallet. 

3D Printing is new. Things are overlooked and sometimes problems can slip through. Therefore at Slant 3D we have a "Baker's Dozen Rule" where we intentionally overproduce on nearly every job to make sure that there are spares and replacements. Just in case.

Once a sample is approved and we have shipped those parts we are responsible for those parts to your doorstep. If they are damaged in transit we will replace them. If they are not up to the specs outlined and agreed upon we will replace them. A supplier should not require oversight. The reason a company uses a supplier is because they think the supplier can do the job better then they could. If we can't then it should be taken inhouse. If we screw up we own it and pay for it.

As the pandemic continues to drag on, we are seeing more and more depression partially from the imposition of current masks. They are uncomfortable, and they really hinder interaction. But the team at TrueContour lead by Jonathan Swartz are looking to change that.

The TrueContour Mask is a fully custom and transparent protective facemask. So it fits to your face perfectly and allows other people to still see you. This not only improves protection from the better fit, but it also improves interaction and human connection, something that seems to be waning with current masks and work at home trends.

The TrueContour is manufactured through a number of steps. First the customer scans their face using the TrueContour app on a iPhone. This scan is then converted into a 3D model that is used as a mold for the mask.

Slant 3D has partnered with TrueContour to produce these molds on demand as orders come in. Our 3D Printing farms, composed of hundreds of 3D Printers, ensure that demand will never outstrip production capacity. 

Once the molds are 3D Printed, then the masks are vacuum-formed and final processing produces the final mask.

This design and method of manufacturing is brilliant. True contour is fixing many of the primary problems with current masks by improving the seal and just allowing people to not look like a bank robber everywhere they go.

They are also taking advantage of a perfectly flexible supply chain brought on by Production 3D Printing and lean manufacturing principles. They will never have excess inventory and will be able to produce perfectly custom items quickly and on demand. We are very excited to be working with such a great and forward thinking company.

TrueContour will be launching via Kickstarter very soon.

Over the last week 3D Printing Stocks got a boost based on a job posting from Tesla looking for an additive Manufacturing Technician. The 3D printing community was abuzz about the idea of one of the most prominent manufacturers in the United States making a push into 3D Printing. Just one problem. This is not new and means nothing.

Tesla has always utilized 3D Printing, both in a prototyping and a production context to make final parts for its cars. The Model Y was shipped with FDM parts modifying its components. Tesla and SpaceX both heavily utilize metal 3D Printing. Musk is not one to shy away from trying to utilize new technology, and never has been.

Now Tesla is certainly a growing opportunity for additive manufacturing. Both through its continued product development and the continuous additions of new plants which could all utilize custom tooling and emergency production. That is why company, including Slant 3D, are expanding operations near Tesla locations.

Overall, this job posting and the rumors around it are indicative of nothing and certainly don't justify a significant change in 3D Printing stock prices.. But we do applaud Tesla on continuing to add to their 3D Printing team. Best of luck to the person that gets the position.

Each year the season comes around. Prime Day, Black Friday, Christmas, New Years. The quarter most consumer companies, big and small, look forward to. Sales spike across, Etsy, eBay, and Amazon.

3D Printing companies this time of year often end up expanding their printing capacity by buying a few more machines. An investment of hundreds or thousands of dollars. The trouble is that after the season passes the machines are left idle. So the investment is not fully utilized. Certainly the machines may be "paid off" but profits are often reduced. And Christmas sales don't often correlate directly with business growth.

This problem is where services are valuable. They are able to bridge the production gap through the season. Clients are able to ramp up their production capacity using Slant 3D printing farms to complement their own. The benefit is there is no cash outlay for equipment that may go unused. The production is perfectly flexible. And the system is profitable on the first part since larger printer farms are often able to access greater economies than smaller 3D printing operations.

This is an especially a good system for small businesses such as Etsy stores. But applies equally well to the industrial sector where sales can spike and production rates need to increase.

Out of Darts reached out to Slant 3D to produce Nerf Dart Hoppers, a large part that absorbs a large amount of Print Time. Slant 3D was able to produce hundreds of the parts over a 2 week period in order to help them meet demand until they could scale up.

But there were challenges. Matching the same output as that associated with Out of Darts was difficult in the time allowed. Since they were using Prusa's and Slant 3D uses our internal Mason there was a conversion process that could've delay the production schedule. Not to mention color matching and other challenges. This is why it is important to prepare the the spike ahead of the need.

Slant 3D can accept quotes today for the christmas season and accept contracts based on need. Sampling and verification can all be completed as well to ensure that everything is ready when it is needed. This helps to prevent delays during the sales spike. 

Slant 3D operates the largest 3D Printing farm in north america. We have a scale that allows any 3D Printed product company to scale up quickly in order to meet the short term demand.

Reach out to us for a quote for your 3D Printed product. And get great for the 4th quarter fun.

It is hard to sell houses. It is a not a decision made quickly. When the customer leaves all they have is a flat floorplan to mull over. And you can't keep a version of every house available for walkthroughs. Combine that with the fact that some people just are not able to visualize 3D spaces very well, and you realize the need for a 3D model of what you are selling.

OK, so the value is pretty clear. 3D Printed Architectural Models improve communication and connection with the buyer. But how are they made?

We first off Slant 3D would need a 3D Model. Ideally your builder or architect can provide 3D models of a building in .STL, .OBJ, or .STEP. Not all architects or architecture software can provide the files for 3D Printing. That is why Slant 3D has an inhouse design team that can take your floorplans and drawings and convert them to a perfectly printable 3D Model.

If your inhouse folks have the ability they can see this article on creating Architectural 3D models for some tips. But do also contact your Slant 3D engineer for more specific information.

Once Slant 3D receives the 3D model then we will prepare it for printing. Our 3D Printing machine are limited in size. So for larger models the building will need to be broken into several pieces, that are printed individually and then slotted together later.

We may also edit some features so that they are manufacturable. This can include tweaking windows and the thickness of the walls.

Lastly if necessary we will work with you to create an removable roof so the inside can be viewed. Though it is perfectly alright to create an exterior-only architectural model. We can 3D Print either one.

That's all there is too it. Send us a 3D model and we can start printing.

Once the model is sent over and finalized we will quote production for you. Whether it be a single large model or thousands of showroom giveaways. Both are equally feasible.

​Hopefully this has cleared up some of the challenges with 3D Printed architectural models. Let us know if you have any questions.

Just the Headband and the transparent shield. That is all that is needed to create a fully functional face shield. This will allow the parts to be produced and assembled more quickly and at a larger scale.

If you would like to secure the mask through more than "spring action" then velcro can easily be adhered to the 3D Printed straps to cinch it down firmly.

This updated design is compatible with the Prusa FaceShield parts as well.

If you would like to 3D Print and assemble this face mask yourself for your local community feel free. Please be sure to exercise precautions such as a mask and glove to ensure that you do not contaminate healthcare personnel.

As COVID-19 continues to spread, 3D Printing can help to mitigate supply shortages of parts and devices needed to help. Slant 3D is comitting a large portion of our production 3D Printing capacity of several hundred printers to help as needed. But there are thousands of other printers in the world that can also contribute.

Here are several 3D printing files that can be printed to help deal with the Coronavirus epidemic.

We would like to take this moment to say that masks are largely ineffective. It is assumed at this point that is Covid-19 is tranmitted predominantly through direct contact with body fluids. This makes a mask useless unless you are in a crowded area among those who are infected and symptomatic. This means that masks are mainly needed in hospitals. 

But if you or a person you know becomes symptomatic you can protect the people around you by wearing a mask because droplets can be spewed around an area through coughing and sneezing. So a mask does help but mainly as a catcher. You do not need to have a HEPA filter simple fabric like a handkerchief in the mask helps a huge amount.

Another interesting mask for holding a cloth cover in place. This mask is printed flat with PLA and then heated with a hairdryer or in boiling water to then form to the face. It will create a more comfortable fit and likely a better seal.

Since the COVID-19 seems to be transfered through direct contact door handles and other common touch-points can be contaminated. Materialize has created a design to be a used with round handled doors which can be easily printed and installed. These fixtures make is easy to open the door with an elbow.

Helping with more general tasks this device allows you to interact with commonly touched surfaces in order to avoid contact. A Simple hook lets you open doors and you can also use it to turn on lights and maybe even the knob in the bathroom.

We will update this list with new posts as more designs are created. We are aslo comitting capacity to the production of such devices. We hope that we can help in some way limit the supply shortages that are arising. If you a have a part that needs to be produced please submit it to us and we will do our best to help.

Most of all we would like to say "Please stay calm." Supply chains are functioning. Infrastructure is fine. It is the burst of panic that has limited toilet paper in the stores. Please only take what you need and plan food and consumables for a potential 2 weeks shutdown. Please do not do more as you will add to a vicious cycle of hoarding. We will come through this epidemic.

Collaborative robots are a great resource for smaller companies looking to automate. They are a flexible resource for completing repetitive tasks in assembly and sorting because of their flexibility and ease of training. The trouble is that robot grippers are not very versatile. Often each task needs its own specialty gripper to be created to grasp the objects in that task.

Creating these grippers is both expensive and difficult due to CAD requirements and machining costs. 3D Printing makes the creation of EOAT much easier and flexible.

3D Printing is a very flexible means of manufacturing EOAT. It allows users to very quickly create custom fingers or parts nests without many machining concerns or time input. That is why Schunk has started providing resources to create custom 3D Printed end effectors. EMI has also started selling 3D Printed EOAT solutions. And there is the Slant 3D Part Mason Project that provides customisable Grippers for Collaborative robots.

Since there are so few design constraints on 3D printed parts you also don't have to worry about high costs of engineering and design bottlenecks.

 Get a Model
At Slant 3D we maintains a team of 3D modelers that can help you design a gripper for your application within hours or days. You can also access pre-made 3D models for gripper fingers and pads at Part Mason. The models are ready immediately to be printed by a service or on your in-house 3D printer.

One other option is to use online resources such as eGrip by Schunk which can generate .STEP files that can be 3D Printed very affordably.