3D Print Prototyping

Your Ideas, Materialized

Close-up of a 3D printer's extruder moving along the print bed, with colorful filament spool and tools in the background.
3D model of a shoe sole with green shoe trees inside, on a 3D printing platform.

Overview

3D printing is a powerful tool for rapid prototyping, enabling fast iteration and functional testing without the high costs of traditional manufacturing. At FormaSharp, we turn well-thought out CAD models into high-quality printed parts using both FDM and resin technologies. Whether you're validating fit and form or preparing for investor presentations, we ensure your prototype is ready to impress.

Colorful playground equipment with a blue base, yellow and red components, situated outdoors in a park with trees and benches in the background.

Capabilities

  • Print Technology: FDM (Fused Deposition Modeling)

  • Build Volume: 250 × 250 × 260 mm

  • Print Speed:

    • Recommended: 300 mm/s

    • Maximum: 600 mm/s

  • Acceleration:

    • Recommended: 10,000 mm/s²

    • Maximum: 20,000 mm/s²

  • Nozzle Specs:

    • Max Temperature: 300°C

    • Standard Diameter: 0.4 mm (supports 0.2, 0.6, 0.8 mm)

  • Hotbed:

    • Max Temperature: 110°C

    • Material: PEI spring steel build plate

  • Extrusion System: Direct drive

  • Leveling System: LeviQ 3.0 Auto-leveling with Z-offset.

3D Printing Workflow

  • CAD 3D model of an exhaust manifold with four tubes connected to a mounting flange.

    CAD Model

    Modelled in SolidWorks for print-ready geometry and precision.

  • Three stainless steel exhaust headers lying on a tiled floor.

    Rendered Image

    Visualized with realistic materials and lighting to preview the final look.

  • 3D model of a complex, organic-shaped object with multiple perforations, shown on a 3D printing slicing software interface.

    3D Print Slicing

    Prepared for printing with optimized layer settings and support structures.

  • Red engine exhaust manifold on white background.

    Final 3D Printed Object

    Physically produced using FDM technology for functional prototyping.

Contact Us
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Design Guidelines

To ensure successful prints, we follow these best practices:

  • Wall Thickness:

    • Minimum 1.2 mm (FDM), 0.8 mm (Resin)

  • Overhangs:

    • Support required for angles >45°

  • Tolerance:

    • ±0.5 mm typical for FDM, ±0.2 mm for resin

  • File Formats Accepted:

    • STL, OBJ, STEP

Applications

  • Functional Prototypes
    Validate mechanical performance, fit, and usability before full-scale production.

  • Fit and Form Testing
    Ensure parts align, assemble, and interact correctly with other components.

  • Concept Models
    Visualize product ideas for presentations, pitches, or internal reviews.

  • Custom Enclosures & Brackets
    Create tailored housings for electronics, sensors, or mechanical assemblies.

  • Jigs & Fixtures
    Design and print tools to aid in manufacturing, testing, or assembly processes.

  • Tooling Inserts
    Print temporary inserts or molds for casting, forming, or silicone molding.

  • Ergonomic Studies
    Produce handheld models to evaluate comfort, grip, and user interaction.

  • Educational Models
    Print anatomical, mechanical, or architectural models for training and teaching.

  • Art & Design Prototypes
    Develop sculptures, jewelry, or decorative pieces for creative industries.

  • Low-Volume End-Use Parts
    Manufacture small batches of functional components for niche applications.

  • Snap-Fit Assemblies
    Test interlocking parts and flexible joints using TPU or PETG.

  • Packaging Mockups
    Prototype product packaging for visual and structural evaluation.