【3D Printing】Bringing Manufacturing 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 paramount.
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 need to be produced quickly and meet stringent requirements.
With the Formlabs Form 4L Stereolithography (SLA) 3D printer, UbeCube can quickly 3D print the robust and durable prototypes needed, as well as the jigs and fixtures to automate their new US factory.
“We are currently focused on bringing production from overseas to our own facility in Grandview, Missouri. As mold making speeds up, our prototyping becomes even more crucial.”
Isaiah Tarwater, Industrial Designer, UbeCube
Bringing Large-Format Prototyping In-House
When industrial designer Isaiah Tarwater joined UbeCube, the company’s internal 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 either outsourced to China or, for faster turnaround, 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, large-format SLA 3D printer could have if owned in-house.
"Before we got the Form 4L, we needed large parts prototyped, and we needed them fast. Sometimes, these parts shipped to the US in batches, taking a month and costing between $3000 and $4000. If we had the same parts produced by printing companies in the US, it would be even more expensive, costing $5000 to $6000,"Isaiah Tarwater said.
For UbeCube, a startup dedicated to creating foldable, stackable, modular storage systems for various environments and applications, cost-effectiveness and time-to-market are paramount.
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 need to be produced quickly and meet stringent requirements.
With the Formlabs Form 4L Stereolithography (SLA) 3D printer, UbeCube can quickly 3D print the robust and durable prototypes needed, as well as the jigs and fixtures to automate their new US factory.
“We are currently focused on bringing production from overseas to our own facility in Grandview, Missouri. As mold making speeds up, our prototyping becomes even more crucial.”
Isaiah Tarwater, Industrial Designer, UbeCube
Bringing Large-Format Prototyping In-House
When industrial designer Isaiah Tarwater joined UbeCube, the company’s internal 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 either outsourced to China or, for faster turnaround, 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, large-format SLA 3D printer could have if owned in-house.
"Before we got the Form 4L, we needed large parts prototyped, and we needed them fast. Sometimes, these parts shipped to the US in batches, taking a month and costing between $3000 and $4000. If we had the same parts produced by printing companies in the US, it would be even more expensive, costing $5000 to $6000,"Isaiah Tarwater said.
| Production Method | Prototyping Cost (per batch) | Lead Time |
|---|---|---|
| Outsourced to China | $3,000–$4,000 | Approximately 1 month |
| Outsourced to US | $5,000–$6,000 | More than 7 days |
| In-house production (Form 4L) | $15–$70 per unit* | Less than 1 day |
Tarwater had previously used Form series 3D printers, so the Form 4L was chosen for its build volume, reliability, and the Formlabs material library.
“Formlabs resin printers are by far the most stable, reliable, and least problematic printers. This reliability, and the fact that we don't have to troubleshoot, saves us an incredible amount of time.”Isaiah Tarwater said.
FDM 3D printing is used for the first few prototypes, assembly testing, and handheld ergonomic testing.
“Once we need a photorealistic prototype, or one where we can actually observe draft angles and take reliable measurements, we switch to the Form 4L. If the part needs to function like an injection-molded part, I'll choose SLA.”Isaiah Tarwater said.
When 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 might need to rotate a quarter turn to be installed.
"At this price point, it's a good deal," Tarwater said.
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 usesTough 1500 Resin. Most of UbeCube's molds are two-part molds without sliders.
This means they focus on moldability in the front-to-back direction and snap-fits.
Therefore, the ability to prototype draft angles and snap-fits is crucial—as is the ability to produce large, single-piece prototypes overnight.
“The vast majority of our products are made from polypropylene, andTough 1500 Resinreally allows us to simulate the properties of that material.”Isaiah Tarwater said.
Tough 1500 Resin is a strong, resilient, and ductile material whose properties are comparable to polypropylene.
Tarwater previously used Tough 1500 Resin V1, but found that the upgraded formulation could withstand repeated cycles without showing stress marks or deformation.
Prototypes printed with Tough 1500 Resin can withstand the repeated cycles required for prototyping and look just like the final injection-molded product.
Toolbox
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 utilizes the entire print volume of the Form 4L (13.9 x 7.7 x 13.8 inches, or 24.2 liters)—prototyping of this scale 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 holds the lid open before it's fully opened.
With the prototype available, Tarwater can "test the friction and protrusion in each iteration.
Even a quarter of a millimeter difference can prevent the lid from opening completely or staying 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 United States.
It will be manufactured using injection molding at 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 that means saving costs by bringing products to market faster, we're willing to put in more effort upfront," Isaiah Tarwater said.
UbeCube is currently focused on moving manufacturing to the US and expanding its factory next door.
Labor is the most expensive cost component in US manufacturing, so UbeCube is automating processes wherever possible.
"If we hired a lot of American workers for assembly and machine monitoring, it wouldn't be economically viable—even with tariffs, we'd still stay overseas. One of the main reasons it's taken us so long to achieve full US production is because we use a highly automated production process. We use a lot of alignment jigs and pneumatic assembly components. With Rigid 4000 Resin, we can print reliable components," Isaiah Tarwater said.
Achieving this automated process includes printing jigs and fixtures that can withstand hundreds of cycles.
For these parts, Tarwater uses Rigid 4000 Resin, a fiberglass-reinforced resin with stiffness similar to PEEK and PEKK thermoplastics, and extremely high heat and chemical resistance.
Accelerating Forward
For an agile startup like UbeCube, bringing products to market as quickly as possible is crucial. In addition to rapidly producing realistic and functional prototypes, Tarwater also works 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 a 3D printed prototype, is very important," Tarwater said.
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, helping automate 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 minimize time-to-market.
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