【3D Printing Application】Ultimaker Customer Success Story: 3D Printed Sustainable Lighting Installations
Ultimaker is a leading global 3D printer brand that received two ISO international certifications in 2018. Its ease of use and stability are consistently recognized by users. It provides a complete 3D printing system solution, including Cura slicing software, built-in filament settings, a cloud platform, and linked monitoring systems. This allows for convenient in-house manufacturing of high-strength, functional prototypes and rapid prototyping.
Below is a customer case study from the brand:
Urban Scale Interventions (USI) is a design studio dedicated to providing human-centered innovation for private and public organizations.
When commissioned to transform seven forgotten locations in Belfast, Northern Ireland, the USI team turned to 3D printing, drawing inspiration from local history to create a lighting experience. Their largest and award-winning installation, "Wine Cellar Entry," transformed the space outside Whites, the city's oldest pub. Once a hub for antisocial behavior, it is now a tourist hotspot and one of the city's most photographed locations.
To kickstart the project, the USI team brought the community together to inform every decision. In a series of public workshops, they surveyed over 1,500 residents to answer one question:
The answers revealed four co-design principles — creating an experience that is "sustainable, playful, interactive, and safe."
Their (now award-winning) installation, 3D printed using Ultimaker, creates a focal point that illuminates one of the hidden gems of Belfast's rich commercial history.
Human-centered Design
Ralf Alwani, co-founder of USI, chose to explore FFF 3D printing after the pandemic outbreak. This technology allowed his team to control all aspects of the design and production process in-house.
"It gives people like us who are not advanced manufacturing experts an opportunity to step into the design-to-manufacture process."
The team quickly realized other benefits. With the ability to visualize the entire installation in 3D using CAD, they had the flexibility to test sculptural ideas and then easily translate these designs to the 3D printer. This production process was not only faster than traditional model making but also effectively eliminated human error.
Art Director Greg Edwards explained, "It's a whole new organic design process for us. We're able to really take these objects from the design table to the streets."
But what exactly are these objects?
An Ocean of Floating Orbs
After testing different forms, the team finally settled on the evocative "ocean orb" design. This relates to Belfast's maritime heritage and the area's history as a fish market.
The team quickly created iterations on-site, allowing them to explore more design options. Alwani explained:
"We can constantly swap out parts, adjust them, and use them in a way that refines our design. The ability to experiment throughout the manufacturing process completely changed the output of the product."
There are a total of 43 orbs, in 3 sizes. Since even the smallest size was still too large for the 330 x 240 x 300 mm build volume of the 3D printer, the orbs were 3D printed in segments. The small size had 3 parts, and the larger sizes had up to 15 parts. In total, approximately 450 parts had to be precisely 3D printed within a tight deadline.
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Deadlines, Despite the Pandemic
The workhorse machines chosen to tackle this monumental challenge? Three Ultimaker S5 3D printers.
"Having the Ultimakers working in the background, it was almost like having an extra pair of hands. It allowed us to move forward with other aspects of the project," said Project Architect Lorna McCarten.
The orbs were 3D printed using transparent PETG made from recycled plastic, with up to 15 segments per orb
Manufacturing flexibility was crucial when new COVID-19 restrictions threatened to delay the project. The team had been working in a former linen mill in downtown Belfast, but the compact, modular nature of the Ultimakers meant production could continue, said Alwani:
"Being able to set up an Ultimaker S5 anywhere was really convenient. When the lockdown came, due to their small size, we were able to move them into an empty room at home and continue manufacturing there without missing deadlines."
Graphic designer Rosanna O'Kane said, "3D printing allowed our team to be hands-on with every step, from design to manufacturing to installation. So, we understood everything about the project and could address issues more easily."
Simple, Sustainable Materials
In addition to reducing environmental impact through local manufacturing, USI further pursued sustainability principles.
They chose to 3D print the translucent PETG orbs from Filamentive (click to find print settings on the Ultimaker Marketplace). This filament is wound on cardboard spools, 89% of which are made from recycled materials—plastic waste that would otherwise have gone to landfills. For every 1 kg of material sold, Filamentive also plants trees to offset at least 1 kg of CO2.
Using only a single translucent material meant that the light bulbs inside each orb could dynamically change colors, harmonizing with the soundscape specifically designed for the installation.
The overall effect created a new sense of place and an instant "Instagrammable" experience for visitors to share!
Urban Scale Interventions won a Placemaking Award for the Wine Cellar Entry installation.
A Brighter Future for Belfast
And the timing couldn't have been better! The installation not only transformed the site into a destination where people could explore and enjoy, but it also gave back to the hospitality industry — one of the sectors hit hardest by COVID-19.
As USI's work raises awareness of the possibilities of additive technology, Alwani sees a positive outlook for the city's creative community:
3D printing offers a new, convenient way to bring manufacturing back into the hearts of Belfast's young people, who are eager to design and reimagine the future.
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