MaxResolution3D fills the gap in an important area of 3D printing – the area between prototyping and large-scale injection molding production – for projects requiring quantities of up to ten thousand parts. To consistently deliver this volume of 3D printed parts, additive manufacturing service providers typically need multiple 3D printers and a large labor force to keep up with demand.

Founded in 2021, MaxResolution3D has set itself the goal of facilitating series production using 3D printing. MaxResolution3D offers companies the ability to produce polymer parts on-site in the center of Europe, using an automated production cell that can deliver 3D printed parts in high volumes with minimal labor.

FormFoundation pointed out a recurring problem with certain trade fair structures: The spotlights hanging above their exhibition stands have brackets that protrude over the advertising panels or walls of the stands and cast unsightly shadows. Previously, employees had to climb ladders and cut around these overhangs, a laborious and time-consuming task for every installation.

The initial search for a solution led them to a metalworking company, but they needed to produce 32,000 parts to achieve a reasonable price per part. In addition, each trade fair exhibit is a one-off production. FormFoundation needed a custom part in the 500-1000 part range and discussed their challenge with MaxResolution3D. The part had to be small – no larger than five centimeters – and mechanically stable enough to hold the large headlight bulbs that were causing the problem. The company also needed the parts for a trade fair stand that was to be set up in just a few days.

Dario Dill, Operations & Digitalization, co-founder of MaxResolution

Michael Wagner, owner and CEO of FormFoundation

When MaxResolution3D founded its manufacturing company in 2021, the biggest challenge was to find a cost-effective 3D printing technology that would deliver the best quality with fast production times. They needed consistent, reliable production for large quantities of parts. And in order to meet the time and cost requirements for the production of large quantities, this solution had to be as simple as possible.

MaxResolution3D chose the NXE 400Pro 3D printer, an industrial resin 3D printing solution with a build volume of 17 liters and production speeds that are up to 6.5 times faster than other 3D printers in the same class. This printer is operated as part of a production cell with a robotic arm that operates three printers simultaneously and transports the build plates with the finished parts to an automatic washing station and then to a storage rack. From there, the only work required is to transport the finished parts to the xCURE for final curing.

When FormFoundation approached MaxResolution3D, the company was well equipped for a project like this that needed to be implemented quickly. MaxResolution3D immediately started the design and tested two iterations before starting series production of the final part. The idea was to develop a thin, four-centimeter-wide part made of x45-Black, a strong and inexpensive synthetic resin material that can support the weight of the headlights.

By introducing the FIM process with the XiP 3D printer from Nexa3D and the xMOLD material, Alpine Advanced Materials benefited from numerous advantages:

Rapid prototyping: FIM enabled Alpine to quickly produce high-quality prototype parts for customer demonstrations and validation tests. The mechanical properties of the FIM parts were exactly the same as those produced with permanent steel tooling, allowing accurate performance evaluation.

Improved strength and surface quality: Compared to directly 3D-printed parts, the parts molded with FIM had a higher strength and surface quality. This makes them suitable for a wide range of applications, including product demonstrations and low volume initial production runs.

Time and cost savings: FIM drastically reduced the time and costs required to manufacture the tools. The exceptional speed of the XiP printer made it possible to produce multiple molds per hour, surpassing the capabilities of conventional CNC machining. Alpine was able to produce 5-10 prototype molds for a fraction of the cost of a production mold, offering significant savings to its customers.

Less risk in material innovation: FIM enabled Alpine’s customers to take a risk-free approach to new thermoplastic materials. Rapidly molded prototypes provided the opportunity for extensive validation testing to ensure the successful introduction of innovative materials.

By using the NXE 400Pro printers and the automation cell, MaxResolution3D was able to increase production reliability to over 97% for 7,000 parts.

Dario Dill, co-founder of MaxResolution3D, said: “Nexa3D’s high print speeds without sacrificing quality and using a lot of material means we can offer our customers the best prices. The functional platform offers the opportunity to make the print jobs more reliable, as we can highly individualize the production process via the technology set up.”

Thanks to this reliability and speed, MaxResolution3D was able to design, print and deliver 500 parts to FormFoundation in just 5 days. After iterating and updating the design, it was uploaded to the automated production cell on Tuesday and the finished parts were delivered to the show on Thursday.

“I don’t think there’s any other technology that can deliver this volume of parts at this speed,” said Michael Wagner, CEO of FormFoundation.

After this project, both FormFoundation and MaxResolution3D agree that this type of innovative manufacturing is already an asset in the design phase.

“If you are confronted with a problem, think outside the box. 3D printing is possible for series production,” says Wagner. “By using it as an option, you get so much flexibility in product development; when you’re faced with problems, you have an accessible solution.”