How to effectively use 3D printing in engineering

3D printing has come a long way – from a technology mainly used for rapid prototyping to a real production tool used in the aerospace, automotive, and medical industries. In our work, we treat 3D printing not only as "printing a model" but as a fully-fledged element of the design and manufacturing process.

Why 3D printing?

• Rapid project verification

  Thanks to the 1:1 scale print, we can check ergonomics, geometry, and assembly before executing an expensive mold or CNC machining.

• Iterability without high costs

  Printing allows for multiple changes and tests – corrections in the design can be implemented immediately, and a new prototype can be on your desk the next day.

• Low-volume production

  In situations where a short series of elements is needed (e.g., spare parts, test elements, custom holders), 3D printing is often cheaper and faster than traditional technologies.

• Design freedom

  Structures with complex geometry, trusses, internal cooling channels – 3D printing enables the realization of what would be practically unfeasible in traditional processes.

How do we use 3D printing in projects?

• Functional prototypes – e.g., suspension components printed in 1:1 scale, tested for assembly and compatibility with other components.

• Show models – product visualizations for clients and investors.

• Production tools and fixtures – quick creation of tooling for assembly lines.

• Spare and upgrade parts – when the cost of producing a single part through traditional machining would be disproportionate.

Technologies we use

• FDM (Fused Deposition Modeling) – rapid prototypes, large components, production fixtures.

• SLA/DLP (Stereolithography/Digital Light Processing) – very high accuracy, ideal for aesthetic or medical elements.

Examples of application in our projects

• Coffee dripper – we prepared a series of prototypes using 3D printing technology, which we then tested during actual coffee brewing. Based on the analysis of the brew – including caffeine content – we modified the arrangement of aeration structures and flow openings. This allowed us to achieve different flavor profiles and optimize brewing time.

• Vehicle suspension – a 1:1 prototype from a 3D printer was used for assembly tests and workspace assessment, allowing us to avoid costly corrections at a later stage of production. After verification and implementing corrections, the suspension was reprinted and used during the Formula Student competition, where it played a functional role in a real vehicle.

• Prototypes of switches for automotive – we created functional and aesthetic prototypes of components that were presented to the final client. The high quality of the prints allowed us not only to check ergonomics and mechanical operation but also to showcase an attractive product appearance in a form very close to mass production.

In summary: 3D printing does not replace traditional production, but it perfectly complements it – it shortens time, reduces risk, and provides design freedom that other technologies do not offer. 

If you want, we can prepare a 3D design for you, conduct simulations, and print a prototype ready for testing or presentation.

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+48 781 790 989

inzynieria@designhere.pl

31 Wincentego Witosa St.

Kraków, 30-612

You can find us.