For companies looking to bring new products to market, prototype testing isn't just a step; it's crucial to avoiding costly mistakes later. We recently completed a prototype printing project for a South African company specializing in supermarket equipment.
Our client had a clear goal: to create a new line of supermarket shopping carts for local stores. Before investing in expensive molds for mass production, they needed prototypes that accurately replicated the final product. This meant that every part, from small connectors to the two largest components, had to be 3D printed as a single piece, with no gluing or assembly allowed. Why? Because gluing parts would create weak points and gaps, making it impossible to test the cart's actual performance. Furthermore, the client wanted the prototype to match the look and durability of the final cart, so they chose white resin—a material that was both strong and durable, and visually aligned with their design vision.
Using white resin for large-scale, single-piece 3D printing is no easy feat. The challenges of this project were:
1. Size limitations of standard 3D printers
Most commercially available 3D printers cannot print parts as large as 552 mm × 433 mm × 875 mm in a single print. Splitting the part into smaller pieces would defeat the customer's "one-piece" printing principle, so we needed equipment that could handle the full size without compromising quality.
2. The Tricky Properties of White Resin
White resin is more demanding than darker materials. It requires precise temperature control to avoid cracking, and slow print speeds can create bubbles or surface roughness—issues that can't be masked on a white part. Worse still, large, one-piece prints rely on the resin to support itself during the curing process; if the resin sags during printing, the entire part is ruined.
How Elite Mold Tech Solved the Problem: Achieving One-Piece Printing Step by Step
Step 1: Selecting the Right Large-Format 3D Printer
We used high-precision, large-format 3D printers designed specifically for large parts. These printers have a large enough build area to print parts as large as 909 mm × 443 mm × 508 mm and 552 mm × 433 mm × 875 mm in a single run. They also feature intelligent stability control, which is crucial for long print runs. Large parts can take hours to print, so consistency is crucial.
Step 2: Fine-tuning the White Resin Printing Process
Before starting the actual print, we conducted multiple tests on the white resin. We adjusted the printer's temperature to ensure even curing and the layer speed to prevent bubbles, which are particularly noticeable in white parts. Our team also checked the resin's viscosity and thickness to ensure smooth flow during printing.
Step 3: Monitor Each Step and Check Quality
During the printing process, our engineers closely monitored progress using the printer's built-in monitoring system. Even minor issues, such as slight layer shift, were immediately corrected to avoid wasting time and material. After the print was complete, we performed two rigorous quality checks:
We used specialized measuring tools to confirm that the part matched the customer's exact dimensions and meticulously inspected every inch of the surface for cracks, uneven spots, or defects. Only parts that passed these two checks were allowed to proceed to the next step.
Result: Satisfied Customer, Ready for Production
The customer was delighted with the shopping cart prototype they received. After testing the part, they confirmed three key features:
1.The one-piece design was durable and sturdy, with no gaps—exactly what they needed to test the cart's structure.
2.The precise dimensions ensured the cart fit the design without any adjustments.
3.The white resin withstood durability tests, proving the shopping cart can withstand the demands of daily use.
Our customers told us, "What we thought was difficult turned out to be easy. These prototypes demonstrated the feasibility of our cart design, and now we're ready to start production. We'll definitely be working with you again on future projects!"
Need large-scale, one-piece 3D printing? Elite Mold Tech has you covered.
Whether you're testing prototypes (like a supermarket shopping cart!) or producing small batches of parts, Elite Mold Tech has the expertise to meet your large-scale, one-piece 3D printing needs. Here's why customers worldwide choose us:
We support a wide range of materials, including white resin, ABS, PLA, and more.
Our team has years of experience working with large parts—no matter the size, we can handle them.
We offer end-to-end service: from design discussions to shipping the finished parts (we take care of it all!).
Ready to make your 3D printing project a reality? Contact us now:
Email: contact@elitemoldtech.com
WhatsApp: +86 19860504405
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