3D Hubs is the world's leading provider of on-demand manufacturing and production. Fillauer Composites, a company that specializes in the production of prosthetic limbs, frequently partners with 3D Hubs to complete their designs. Fillauer makes use of 3D Hubs' plastic, nylon, and metal 3D printing capacities to source custom parts without delaying their internal production processes.
The complications of carbon fiber
Fillauer Composites makes most of their prosthetics out of a combination of carbon fiber, fiberglass, and metal alloys. Carbon fiber is a strong and durable material with a high heat tolerance; it can also be used to create the unique shapes demanded by prosthetic designs. This makes it an excellent choice for the sleek and sturdy prosthetic limbs demanded by athletes and professionals alike.
Unfortunately, carbon fiber isn't particularly easy to work with. Small errors in the manufacturing process can result in flaws across the production line. Fillauer's engineers spend most of their time creating prototypes and tweaking assembly lines to get the exact conditions needed for successful manufacturing.
Shaving time off the design process
The manufacturing room at Fillauer Composites is completely devoted to carbon fiber production. Their equipment includes machining tools, a water jet to cut materials, and an autoclave to cure finished products. These machines are almost always in use, and the engineers spend their time refining the production cycle.
This means that if Fillauer needs a unique part or prototype that doesn't fit into their normal processes, they don't necessarily have the resources to make it. When that happens, their engineers turn to a 3D printing service to get the job done.
How 3D Hubs is able to help
Fillauer Composites works with 3D Hubs to source small batches of parts made with 3D printing and large batches of parts made with injection molding. There are several reasons why 3D Hubs makes a great manufacturing partner:
Quick prototypes
Quick prototypes - Prototypes are an essential part of the design cycle, but the engineers at Fillauer Composites are already pressed for time. 3D Hubs is able to deliver both functional and aesthetic prototypes with extremely short lead times. This lets Fillauer's engineers go through multiple iterations before they decide on a final design, all while remaining on schedule.
Complicated shapes
Complicated shapes - Some of the shapes that Fillauer Composites needs are simply too complicated to create with their in-house equipment. Their prosthetics often include small plastic widgets, attachment brackets, and other unconventionally shaped items. 3D printing is the perfect choice for detailed and geometrically complex shapes that would be difficult or expensive to produce with other methods.
Unique designs
Unique designs - 3D Hubs' transparent manufacturing process makes it easy for Fillauer Composites to create parts with unique forms and functions. Fillauer will describe the necessary functions of a part, and the engineers at 3D Hubs will help make it a reality. This lets Fillauer's engineers get back to work on their end of the project.
Material options
Material options - 3D printing isn't just for plastic parts. Fillauer has made use of plastic, nylon, and even metal 3D printing processes to source the custom parts needed for their prosthetics. This is particularly useful when they need a small batch of parts and don't want to tie up their internal production processes.
Fillauer Composites relies on 3D Hubs 3D printing service to get functional parts created as quickly as possible. The partnership has reduced their overall production costs, shortened the design cycle, and freed up extra time for their engineering team.
See how 3D Hubs can help your design process - upload a CAD file to the online manufacturing tool, and receive an instant quote and manufacturing analysis today.
