Our Work
See below for some of our most relevant projects, and feel free to reach out if you are looking for production examples tailored to specific industries!
Robotic laser welding
This project involved the production of a custom gas nozzle and mounting plate assembly for an industrial robotic laser welding process. The components were optimized for metal additive manufacturing to achieve complex internal and mounting geometries while maintaining tight dimensional tolerances. For the mounting plate, post-processing included water bonding, as the original design exceeded the printer’s height capacity and was printed in two sections. The result was a reliable, non-porous, production-ready assembly capable of operating in elevated-temperature conditions where polymer prototypes had previously failed.
Drone-based solar panel washing
AM3D designed and produced a lightweight, mechanically robust nozzle mounting assembly for a drone-based solar panel cleaning application. Without existing digital designs, we began by measuring key drone geometries, manually building CAD models for the joint and nozzle mount, and iterating through multiple prototypes to verify fit and functionality. Using FEA simulations, the design was optimized for low mass, high stiffness, and vibration resistance, ensuring flight stability while supporting pressurized fluid delivery. The final component enabled our client to move quickly from concept to field testing.
Automation gripping fingers
We produced a set of custom robotic gripping fingers tailored to a specialized automation system. The fingers were manufactured using 316L stainless steel, providing critical corrosion resistance, high strength, and remarkable dimensional accuracy and surface finish, particularly impressive given the parts’ compact size and MPD's struggle with fine features. This project highlights the advantages of additive manufacturing for rapid customization, cost-effective solutions (lower cost than machined metal tooling), and fast turnaround in the event of wear or design changes.
Welding automation
This project focused on a push plate used in an automated welding cell, where dimensional accuracy, thermal resistance, and mechanical strength were critical. After plastic prototypes proved unsuitable due to high-temperature exposure, the part was redesigned for additive manufacturing. Using paste-based metal printing, we produced a dense, non-porous component capable of reliable performance in a high-temperature industrial environment. The result was a durable, production-ready tool, fully integrated into the client’s automation workflow.
Mobile robotics R&D
AM3D supported R&D efforts by producing custom reinforced components (an enclosure and a belt-drive pulley) for a mobile robotics system. The enclosure was optimized for shock absorption using Kevlar reinforcement, while the pulley required tight tolerances, excellent surface quality, and high strength for reliable power transmission, all achieved with Onyx reinforced with carbon fiber. Projects like this demonstrate how additive manufacturing enables rapid design iterations, short lead times, and functional testing without the delays of traditional machining.
Open-ocean electronics housing
For offshore deployment, AM3D manufactured an electronics housing designed for harsh open-ocean conditions. The part required excellent dimensional accuracy, reliable sealing interfaces, and long-term corrosion resistance. Metal AM was chosen to produce a fully dense, non-porous structure suitable for marine environments. The housing was post-processed to achieve the necessary surface finish and mating tolerances, enabling the safe integration of sensitive electronics in a high-humidity setting, without the costs or lead times associated with traditional tooling or molding.
QA go-no go gauges
This project involved the production of custom dimensional inspection gauges for quality assurance of glass products. Using reinforced plastic 3D printing, we delivered lightweight, rigid, and smooth tools with ±0.1 mm accuracy, suitable for repetitive shop-floor use. The gauges enabled our client to perform fast pass/fail inspections directly on the production line, reducing measurement time and improving consistency.
Custom spatter guard
AM3D designed and manufactured a custom copper spatter guard for an East Coast client developing small-scale automation systems. This application required high thermal conductivity and resistance to molten metal adhesion. Copper was selected for its excellent heat dissipation and durability in high-temperature environments. The part geometry was optimized for additive manufacturing using generative design, achieving features difficult to machine conventionally while maintaining functional performance and efficient material usage.
