| Challenge: From Prototype Bottlenecks to Innovation Flexibility
Innoseal Europe BV, a leader in developing and producing tape-related packaging solutions, faced a common challenge in product development: balancing quality, lead times, and costs in the journey from design to production.
Initially, the company adopted FDM 3D printing for testing and prototyping. While this offered some early benefits, it quickly became apparent that the quality of the resulting parts was insufficient for functional testing or small-scale production.
Traditionally, Innoseal had to wait for a significant surge in market demand before committing to expensive injection molding tools – a process requiring substantial upfront investment with uncertain outcomes. To mitigate risks, they began outsourcing 3D printing, but inconsistent lead times and concerns about intellectual property leakage hampered innovation.
|Solution: Choosing Lisa X and SLS Freedom
In search of an affordable, user-friendly, and open-material SLS 3D printing ecosystem, the Innoseal team explored available technologies. Their evaluation led them to Sinterit Lisa X.
“We researched other 3D printing methods and brands but ultimately opted for SLS and chose Sinterit because of their smooth communication and the variety of open material options they offer. This was something we couldn’t find with other affordable entry-level SLS printer providers,” Daniel Aarts, Technical Director at Innoseal Europe, recalls.
The decision was sealed after a visit to Sinterit’s factory in Poland. “Seeing the production process firsthand and talking to the team gave us a lot of confidence in the product and the people behind it.”
Lisa X Performance Set in Innoseal's working environment
|Application: Functional Parts, Prototypes, and Small Series
Today, Innoseal primarily uses the Lisa X to produce small functional parts made from PA11 CF, prototypes, and small batches of products until production volumes reach a point where they can transition to injection molding. With the Lisa X printing 1-2 times per month on average, with batches ranging from 10 to 50 parts, it has become a cornerstone of their R&D and small-batch production.
“It makes no sense to calculate a direct ROI in our case, with the scale at which we use the SLS printer. However, the possibilities for innovation and testing new concepts have become so much easier. Running a quick test or improving an existing design now takes days, not weeks,” says Daniel Aarts.
The complete Sinterit ecosystem, including the Powder Handling Station (PHS) and a Sandblaster, simplifies post-processing. Despite the complex geometries of Innoseal’s parts, often featuring small holes and internal chambers, post-processing is highly efficient. “For CF nylon, which is inherently a bit rougher, we are very satisfied with the surface quality,” says Daniel Aarts.
Parts printed with Sinterit LISA X printer:
1. Push block and one-way lock
2. Tape wheel
3. One-way lock block
Parts printed with Sinterit LISA X printer:
1. Custom-sized tape roll holder 2.Paper guide block 3. Pulleys and background push block and one-way lock
Parts printed with Sinterit LISA X printer:
1. Tape wheel assembled with pulleys
2. "Tape wheel" assembled with "push rod" and "one-way lock"
3. Paper clamping mechanism with automatic release
|Impact: Faster Innovation, Reduced Risk, and Cost Savings
The implementation of Lisa X has yielded measurable benefits:
Reduced rework of new tooling by verifying parts before mold production.
Increased flexibility and time to market, especially for complex components.
Accelerated design iteration cycles, saving 3-5 days per design revision.
“This may not sound like much, but over multiple revisions, it adds up to a significant amount of time,” explains Daniel Aarts, Technical Director at Innoseal Europe. “If we had to wait for outsourced milling or turning after every change, we would have lost more than 18 weeks over the past year.”
Perhaps most significantly, the Lisa X has empowered Innoseal to experiment more boldly. “We can now try out ‘crazy’ ideas that we previously wouldn’t have considered due to financial limitations. If the print volume is large enough and the refresh rate is sufficient, why not print it and give it a try?”
|Favorite Feature: Worry-Free Printing
Daniel emphasizes that the ability to start a print and walk away is one of the most valued features of the Lisa X. Unlike FDM, where adhesion issues can ruin long prints, the Lisa X offers reliability and peace of mind.
“No need to wait in front of the print bed to see if the first layers stick. A 48-hour print will not fail. This alone has saved us countless hours and unnecessary hassles.”
|Bonus Interview: Lessons, Surprises & Future Plans with LISA X
Curious about what it's really like to use LISA X every day? In this exclusive video, Daniel Aarts, Technical Director at Innoseal, shares what surprised them most in the first few months, how the printer has changed their prototyping approach, and how it has made daily operations smoother than expected. You'll also hear their advice for companies considering purchasing their first SLS 3D printer, and get a glimpse into the future of SLS at Innoseal and beyond.
Watch and get inspired by real-world experience!
|Final Thoughts
"Sinterit's Lisa X allows us to shorten lead times and create better solutions faster, helping us meet our customers' needs," concludes Daniel Aarts.
For Innoseal Europe, investing in Lisa X is more than just printing parts. It's about unlocking innovation, reducing risk, and gaining the flexibility to keep pace with their ideas.
