3D printing for lightweighting — topology optimization and lattice structures.
Traditional manufacturing forces solid geometry because molds and machines cannot produce internal structures. 3D printing can. Our design engineering service applies topology optimization and lattice infill strategies to reduce part weight by 30–60% while maintaining the stiffness and strength your application requires.
Challenges we solve
What lightweighting teams need from a 3D printing service
Maintaining structural performance with less material
Lightweighting is not hollowing. Our topology optimization preserves load-carrying capacity while removing material from non-structural regions. Every lightweighted design is validated against your load case.
Designing manufacturable lattice structures
Not every lattice geometry is printable. We design lattice structures matched to the capabilities of our production platforms — ensuring the lightweighted geometry actually prints successfully.
Validating lightweighted designs
We produce prototype lightweighted parts for physical testing. Compare weight, stiffness, and strength against your original solid design before committing to production.
Balancing weight reduction with manufacturing cost
Maximum weight reduction and minimum cost are often competing objectives. We find the optimal balance for your application — the lightest part that meets your performance and cost requirements.
Materials
Materials for lightweighting
Nylon PA12 on MJF for production lightweighted parts — consistent mechanical properties and excellent fatigue resistance. PC CF for maximum stiffness-to-weight ratio. Nylon PA12 Glass Filled for lightweighted parts requiring higher thermal performance.
Nylon PA12
MJF · Shore D 73
Strong, lightweight, chemical resistant. The standard for functional end-use parts. Excellent fatigue resistance and consistent mechanical properties.
PC CF
FDM · Shore D 83
Polycarbonate carbon fiber. High stiffness and heat resistance for demanding structural applications.
Nylon PA12 Glass Filled
MJF · Shore D 82
40% glass-filled nylon. High stiffness and thermal stability for demanding structural applications.
Common parts
What we build for lightweighting
Built in our factory
Brooklyn, NY
How it works
Your project, step by step
Submit geometry & loads
Send current part geometry with load cases, constraints, and weight reduction targets.
Topology optimization
Our engineering team runs optimization and designs the lightweighted geometry with appropriate lattice structures.
Design review
You review the optimized geometry, weight savings, and predicted performance before printing.
Prototype & test
Lightweighted prototype produced for physical validation against your original design.
Production
Validated lightweighted design produced at volume.
FAQ
Frequently asked questions
How much weight can be reduced?
Typically 30–60% depending on the original design and load case. Parts with large solid sections and simple load cases see the highest reduction.
Does lightweighting affect part stiffness?
Topology optimization maintains stiffness along the primary load paths. Stiffness in non-load-bearing directions may be reduced — which is the point.
Can lightweighted parts be produced at volume?
Yes. MJF Nylon PA12 handles lattice structures reliably at production volumes with consistent mechanical properties across the batch.
Other applications
Rapid Prototyping
Functional prototypes in 2–3 business days. Test form, fit, and function before committing to tooling.
Production Parts
Production-grade 3D printed parts at volume — without tooling investment.
Hardware Development
One vendor from first prototype to production parts — no retooling, no requalifying.
Large Format 3D Printing
Single pieces up to 1200mm — or seamless multi-part assemblies at any scale.
Tooling & Fixtures
Custom jigs, fixtures, and assembly aids — delivered in days, not weeks.
Bridge Manufacturing
Ship real product now. Transition to injection molding when you are ready.
Replacement & Spare Parts
Reproduce legacy parts, replace obsolete components, and eliminate spare parts inventory.
Custom Enclosures
Custom enclosures with snap-fits, bosses, and ventilation — production-grade, no tooling.
Low Volume Manufacturing
Manufacture 10 to 5,000 parts without tooling — scale up or down order by order.
Presentation Models & Props
Presentation-quality models, trade show props, and display pieces — finished and delivered on time.
Casting Patterns
3D printed casting patterns — clean burnout, fine detail, no traditional pattern tooling.
Medical & Anatomical Models
Anatomical models, surgical planning aids, and medical training tools — dimensionally accurate.
End-Use Consumer Products
Ship real products to real customers — without injection mold tooling.
Design Verification & Testing
DVT and EVT builds in production-representative materials — validate before you tool.
Product Design Validation
Test form, fit, and function with production-grade materials before committing to tooling.
Investor Samples
Presentation-quality parts that look and feel like the final product — built for boardrooms, pitch decks, and demo days.
Pre-Production Testing
Validate tolerances, material behavior, and assembly flow at low volume before committing to production.
Jigs and Fixtures
Custom tooling for your production line — printed and delivered in days, not weeks.
End-Use Production Parts
Parts that go directly into products your customers buy and use — not prototypes, not samples.
Supply Chain Supplementation
Fill gaps in your supply chain without retooling or waiting months for overseas shipments.
Low-Volume Serial Production
Hundreds to thousands of identical parts — no MOQ from a mold shop, no tooling investment.
Replacement Parts Programs
On-demand spares for legacy and current products — without warehousing inventory.
Architectural Models
Site models, facade studies, and presentation pieces at true scale — printed whole or assembled seamless.
Trade Show Builds
Oversized displays and product replicas built to withstand transport and handling — show-ready finish.
Industrial Housings and Enclosures
Full-size prototypes of panels, covers, and housings — validate before committing to sheet metal or tooling.
Tooling and Molds
Large-format mold masters and lay-up tools — printed faster than machined.
Props and Set Pieces
Camera-ready props for film, TV, and commercial production — on tight timelines.
Wind Tunnel Models
Dimensionally accurate aerodynamic test models at scale — smooth surfaces, tight tolerances.
Legacy Part Replacement
Reverse-engineer and reproduce discontinued parts from scans or drawings — no original tooling needed.
Part Consolidation
Combine multi-part assemblies into single printed components — fewer parts, fewer failure points.
Manufacturability Analysis
Evaluate your design for printability before committing to a production run.
Scan-to-CAD
Point cloud in, watertight solid out — production-ready CAD from any 3D scan.
Tooling Design
Custom jigs, fixtures, and mold masters — designed from scratch for additive manufacturing.
Fixture Optimization
Redesign production fixtures to reduce weight, improve ergonomics, and speed up assembly.
Plan Your Project
Tools to plan your build
Check shipping transit times, estimate lead times by technology, and review design guidelines before you upload — so your parts print right the first time.
Check Transit Time
Enter your zip code to see how fast parts arrive from our Brooklyn facility.
Ready to start your lightweighting project?
Upload your CAD file and get a quote in minutes — or talk to our engineers about your next production run.