These are our 3D printing case studies. Every one started as somebody else's problem: a part that costs too much, a print that takes too long, a model that has to survive the North Sea. Each one is written up in full — the brief, the engineering decisions we made, and what actually happened once it was in use.
Selected projects
Conservation, automotive repair, veterinary teaching, manufacturing throughput and youth training. Filter by sector, or read them all.
Ørsted needed lifelike kittiwake decoys that could survive years on offshore nesting structures in the North Sea. We reverse engineered an anatomically accurate model, printed 66 units in recycled PETG, and weatherproofed them for marine conditions.
Manufacturers hit a capacity ceiling and assume the answer is more machines. We review G-code, print profiles, bed layout, material choice and machine configuration — and on one client's existing hardware took a 24-hour production print down to 12, with no loss of strength for the application.
Our student Neil Doherty won the 2026 Sanjay Mortimer Foundation Rising Star Award at the TCT Awards — the youngest winner in its history — after three years that took him from complete beginner to designing and selling products now used in local businesses.
The replacement housing for a Fiat Panda was available — but its price would have pushed the repair past what the insurer had approved. We scanned the intact housing on the opposite side of the car, rebuilt it as clean CAD, and printed the replacement in ASA glass fibre.
Calweton Veterinary Group needed to teach difficult birthing procedures without a live animal. We scanned a cow hip bone and a lamb hip bone, redesigned both to be printable, and have produced them for the practice ever since.
No projects in that sector yet.
How a project runs
We start from the real object wherever one exists — 3D scanning the original, a matching part, or the mating surfaces it has to fit against. That is what keeps a reverse engineered part dimensionally honest.
The CAD is rebuilt cleanly rather than traced, then adapted for manufacture: wall thickness, orientation, tolerances and material chosen for the load, the environment and the budget the part has to live inside.
We print in-house, check it fits, and change what needs changing. Several of the projects here are still in repeat production years after the first part was delivered.
Whether it is one obsolete part, a production run that is taking too long, or something nobody has made before — tell us what you are trying to solve and we will tell you honestly whether 3D printing is the right answer.
