Solving Modern Engineering Challenges

Being in the automation industry for over 25 years, we know that custom machine building comes with unique challenges—tight timelines, complex requirements, and the constant need to balance innovation with reliability. Every machine is tailor-made, leaving little room for error and even less for delay. Fast design phases and consistent design verification are essential for producing functional, high-efficiency systems on schedule.

Development cycles are often driven by tight deadlines and evolving requirements, making it essential for engineering teams to iterate quickly and adapt on the fly. The ability to test a design, identify flaws, and execute improvements—without waiting weeks for a machined part—can significantly reduce project delays and improve final outcomes. Our team uses in-house 3D printing for rapid prototyping, enabling agility and allowing designers to move from Computer Aided Design (CAD) to a physical component in a matter of hours or days.

Rapid Prototyping in Machine Design

Traditional prototyping methods can be slow, costly, and rigid. Waiting on machined components not only ties up resources, but also limits the number of design iterations that can feasibly occur within a development window. Each change often requires new tooling, extended lead times, and added expense. In contrast, rapid prototyping—especially through 3D printing—dramatically shortens that feedback loop. Engineers can quickly validate fit, form, and function, catching issues early in the process before they become costly.

That’s where 3D printing steps in. As a powerful tool for rapid prototyping and early-stage development, 3D printing enables our team to test, refine, and validate concepts faster than ever before. By incorporating it into the workflow, custom machine builders like us streamline development and gain early design assurance ahead of manufacturing.

Using 3D Printing to Advance Concept Design

Digital fabrication plays a crucial role in the concept development phase of custom machine design by turning digital ideas into tangible models—quickly and cost-effectively. When working with complex assemblies or motion systems, it can be difficult to fully visualize spatial relationships and part interactions from CAD alone. With 3D printing, engineers can create scaled or full-size mockups early in the process, helping teams identify potential design issues, validate clearances, and ensure smoother integration of mechanical, electrical, and robotic systems before committing to costly parts.

Beyond visualization, 3D printing also enables the creation of functional proof-of-concept parts or subsystems. Whether it’s a fixture prototype, a robotic end-of-arm tool, or a simulated conveyor section, designers can test fit, movement, and ergonomics in the real world—without tying up the machine shop.

For example, printed mockups are often used to evaluate robot reach, optimize toolpaths, or confirm part orientation within nests or pallets. These physical representations offer immediate feedback and inform smarter design decisions, all while accelerating the development cycle and reducing the risk of rework later on.

What’s Included in a Design Blueprint?

At SDC, every technical drawing includes key elements to ensure clarity, manufacturability, and compliance with industry standards:

  • Title Block – Project and part name, drawing number, date, scale, units, and designer’s name
  • Dimensions & Tolerances – Exact measurements and acceptable deviations for production
  • Views – Front, top, and side (orthographic), plus isometric or section views as needed
  • Annotations – Notes on materials, finishes, manufacturing steps, and assembly instructions
  • GD&T – Geometric dimensioning and tolerancing to define form, fit, and function
  • Bill of Materials (BOM) – For assemblies, a list of components with part numbers and quantities
  • Revision History – A log of updates to ensure the most current design is used

Including all of these elements ensures every machine we build is backed by precise, production-ready documentation that sets the foundation for a successful build.

Cost and Efficiency Advantages

3D printing offers significant cost and efficiency advantages in custom machine design by:

  • Dramatically reducing the time required for design validation
  • Accelerating feedback loops
  • Enabling faster decision-making

Beyond saving time, 3D printing helps reduce scrap and costly rework. Early detection of design flaws through physical prototypes means fewer mistakes make it to final production, minimizing wasted materials and labor. This precision also lowers the risk of expensive downstream corrections. Importantly, 3D printing empowers our engineers to explore innovative ideas with fewer constraints, encouraging experimentation and creative problem-solving. By removing traditional barriers such as tooling costs and machining lead times, it opens the door for more flexible, efficient, and cost-effective machine development.

The Future of Custom Machine Building Starts Here

In today’s fast-paced manufacturing environment, staying agile and innovative is key to maintaining a competitive edge. 3D printing has become an indispensable tool in custom machine building, significantly enhancing both concept development and design validation. By enabling fast, flexible prototyping, it allows our engineering teams to visualize complex assemblies, test functional components, and iterate quickly—all while reducing costs and minimizing risks. This approach leads to smarter designs and more reliable machines built on a foundation of real-world feedback rather than guesswork.

Work with Us

At SDC, we leverage SolidWorks and 3D printing to bring your machine concepts to life faster and with greater design confidence. If you’re looking to accelerate development, validate ideas early, and reduce risk before production, let’s collaborate. Together, we can turn your custom automation vision into a reality—quickly, accurately, and efficiently.

FAQ

Why does SDC use 3D printing in custom machine projects, and how does it benefit customers?

SDC uses 3D printing because it enables faster, more agile development in the face of complex engineering challenges and tight timelines. Traditional prototyping methods are often slow and expensive, limiting design iterations and delaying progress. In contrast, 3D printing allows our engineers to move quickly from digital CAD models to physical components—sometimes in just hours—so they can test, refine, and validate designs early in the process. 

This rapid prototyping improves fit, form, and function testing, uncovers design issues sooner, and reduces costly rework. It also enhances visualization and integration of complex assemblies, leading to smarter design decisions and more reliable machines. For our customers, this means faster project timelines, reduced development costs, and greater confidence that the final machine will perform as intended. 

What advantages does 3D printing bring to the custom machine design process?

3D printing accelerates prototyping, allowing engineers to quickly move from CAD models to physical components. This rapid turnaround supports early design validation, helps catch issues before production, and enables faster iterations—ultimately reducing delays and development costs.

How does 3D printing reduce project risk?

By enabling physical validation early in the design process, 3D printing reduces the risk of errors making it to the production floor. It minimizes the need for rework, shortens feedback loops, and ensures designs are sound before investing in machining or tooling.

Is 3D printing just for visual mockups, or can it support functional testing?

It’s useful for both. While 3D-printed parts are often used for fit and visualization, they can also support functional testing of components like fixtures, robotic end-of-arm tools, and motion mockups. This helps validate movement, reach, ergonomics, and part orientation in real-world conditions.That’s where 3D printing steps in. As a powerful tool for rapid prototyping and early-stage development, it enables engineers to test, refine, and validate concepts faster than ever before. By incorporating 3D printing into their workflow, custom machine builders streamline development and gain early design assurance ahead of manufacturing.