【3D Printing】How to Bring Manufacturing Back to the US with Formlabs 3D Printed Prototypes
For UbeCube, a startup dedicated to creating foldable, stackable, modular storage systems for various environments and applications, cost-effectiveness and time to market are crucial.
To achieve these goals, they not only moved large-scale functional prototyping in-house but also shifted production to the United States.
From working prototypes to production jigs and fixtures, parts needed to be produced quickly and meet stringent requirements.
With the Formlabs Form 4L Stereolithography (SLA) 3D printer, UbeCube was able to quickly 3D print the robust and durable prototypes needed, as well as jigs and fixtures for automating their new US factory.
“We're currently working on bringing production back from overseas to our own facility in Grandview, Missouri. As mold making speeds up, our prototyping has become even more critical.”
Isaiah Tarwater, Industrial Designer, UbeCube
Bringing Large-Format Prototyping In-House
When industrial designer Isaiah Tarwater first joined UbeCube, the company's in-house print lab only had two low-cost resin 3D printers.
He later introduced two Bambu Lab P1S FDM 3D printers, but large prototypes requiring SLA printing were outsourced to China, or, to shorten lead times, printed locally in the US.
While overseas printing was cheaper than outsourcing 3D printing in the US, lead times could be up to four times longer.
Tarwater realized the immense impact a fast, reliable, and large-format SLA 3D printer in-house could have.
"Before we got the Form 4L, we needed to prototype large parts and get them as quickly as possible. Sometimes, these parts shipped in batches to the US would take a month and cost between $3,000 and $4,000. If printed by a US printing company, the same parts would cost even more, between $5,000 and $6,000," says Isaiah Tarwater.
For UbeCube, a startup dedicated to creating foldable, stackable, modular storage systems for various environments and applications, cost-effectiveness and time to market are crucial.
To achieve these goals, they not only moved large-scale functional prototyping in-house but also shifted production to the United States.
From working prototypes to production jigs and fixtures, parts needed to be produced quickly and meet stringent requirements.
With the Formlabs Form 4L Stereolithography (SLA) 3D printer, UbeCube was able to quickly 3D print the robust and durable prototypes needed, as well as jigs and fixtures for automating their new US factory.
“We're currently working on bringing production back from overseas to our own facility in Grandview, Missouri. As mold making speeds up, our prototyping has become even more critical.”
Isaiah Tarwater, Industrial Designer, UbeCube
Bringing Large-Format Prototyping In-House
When industrial designer Isaiah Tarwater first joined UbeCube, the company's in-house print lab only had two low-cost resin 3D printers.
He later introduced two Bambu Lab P1S FDM 3D printers, but large prototypes requiring SLA printing were outsourced to China, or, to shorten lead times, printed locally in the US.
While overseas printing was cheaper than outsourcing 3D printing in the US, lead times could be up to four times longer.
Tarwater realized the immense impact a fast, reliable, and large-format SLA 3D printer in-house could have.
"Before we got the Form 4L, we needed to prototype large parts and get them as quickly as possible. Sometimes, these parts shipped in batches to the US would take a month and cost between $3,000 and $4,000. If printed by a US printing company, the same parts would cost even more, between $5,000 and $6,000," says Isaiah Tarwater.
| Production Method | Prototyping Cost (per batch) | Lead Time |
|---|---|---|
| Outsourced to China | $3,000–$4,000 | Approx. 1 month |
| Outsourced to US | $5,000–$6,000 | 7+ days |
| In-house (Form 4L) | $15–$70 per unit* | Less than 1 day |
Tarwater had previously used Form series 3D printers, so he chose the Form 4L for its build volume, reliability, and the Formlabs material library.
"The Formlabs resin printers are by far the most stable, reliable, and least likely to fail. This reliability, and not having to troubleshoot, saves us an incredible amount of time," says Isaiah Tarwater.
FDM 3D printing is used for the initial few prototypes, assembly testing, and handheld ergonomic testing.
"Once we need a photorealistic prototype, or a prototype that can actually show draft angles and allow for reliable measurements, we switch to the Form 4L. If the part needs to behave like an injection-molded part, I choose SLA," says Isaiah Tarwater.
For prototyping on the Form 4L, Black Resin (a General Purpose Resin) is used for parts that don't need to withstand tensile or torsional forces, but may need to rotate a quarter turn to install.
"At this price point, it's a great deal," says Tarwater.
Another General Purpose Resin – Clear Resin – is used for visual prototypes of lids that will be manufactured from polycarbonate.
Snap-Fit Design with Tough 1500 Resin
Functional prototyping uses Tough 1500 Resin. Most of UbeCube's molds are two-piece molds without sliders.
This means they focus on moldability and snap-fit in the front-to-back direction.
Therefore, the ability to create draft angles and snap-fits on prototypes is crucial – as is the ability to produce large, single-piece prototypes overnight.
"The vast majority of our products are made from polypropylene, and Tough 1500 Resin allows us to truly simulate the characteristics of this material," says Isaiah Tarwater.
Tough 1500 Resin is a robust, resilient, and ductile material whose performance is comparable to polypropylene.
Tarwater previously used Tough 1500 Resin V1, but found that the upgraded formula could withstand repeated cycles without stress marks or deformation.
Prototypes printed with Tough 1500 Resin can endure the repeated cycles required for prototyping and look like the final injection-molded product.
Tackle Box
UbeCube's tackle box prototype, measuring approximately 12.5 x 12.5 x 4 inches, was created using the Form 4L printer and Tough 1500 Resin.
The tackle box fully utilizes the Form 4L's entire print volume (13.9 x 7.7 x 13.8 inches, or 24.2 liters) – prototyping of this size was simply not possible in-house before the Form 4L.
Printing with Tough 1500 Resin means it's a fully functional prototype.
The lid of the box has a support point in the middle that props up the lid before it fully opens.
With a working prototype, Tarwater can "test the friction and protrusion with each iteration.
Even a difference of a quarter millimeter can mean the lid doesn't open all the way or won't stay propped open.
Cost-Effective US Manufacturing with 3D Printed Jigs and Fixtures
This tackle box will be UbeCube's first product fully designed and manufactured in the US.
It will be manufactured using injection molding in UbeCube's new factory – with jigs and fixtures also 3D printed on the Form 4L.
"We don't have time to wait for overseas factories to complete a mold, which takes nine months to a year. We need to get molds as quickly as possible. So, if it means saving costs by getting products to market faster, we're willing to invest more effort upfront," says Isaiah Tarwater.
UbeCube is currently working on relocating manufacturing to the US and expanding into the factory next door.
Labor is the most expensive cost component in US manufacturing, so UbeCube is automating processes as much as possible.
"If we hired a large number of US workers for assembly and machine monitoring, it wouldn't be economically viable – even with tariffs, we'd still remain overseas. One of the main reasons it's taken us so long to achieve full US production is our highly automated production process. We use a lot of alignment jigs and pneumatic mounting components. With Rigid 4000 Resin, we're able to print reliable components," says Isaiah Tarwater.
Achieving this automated process involves printing jigs and fixtures that can withstand hundreds of cycles.
For these parts, Tarwater uses Rigid 4000 Resin, a glass-fiber reinforced resin with stiffness similar to PEEK and PEKK thermoplastics, and extremely high heat and chemical resistance.
Accelerating Forward
For agile startups like UbeCube, getting products to market as quickly as possible is crucial. In addition to rapidly producing realistic and functional prototypes, Tarwater is also working on adding textures to parts to simulate the effect of foaming agents used in injection molded products.
"Being able to produce something that looks exactly like the final product, rather than relying solely on 3D printed prototypes, is incredibly important," says Tarwater.
With photorealistic prototypes, photos can be taken before product delivery, shortening time to market.
Using the Form 4L for 3D printed jigs and fixtures also increases UbeCube's speed, aiding in the automation of its US manufacturing while saving labor costs and time to acquire tools.
By bringing 3D printing in-house, UbeCube can control timelines, improve cost savings, and maximize time to market.
Learn more about Formlabs products 👈
- Contact Us -
3DMART provides more than just 3D printing, we offer three major OEM services: "3D Printing Service", "3D Scanning Service", and "360-degree Space Scanning Service"!!
Follow our fan page to stay updated:
Facebook | Instagram | Threads