Rapid Prototyping a Better Ride with Custom 3D Printing
Rapid Prototyping a Better Ride with Custom 3D Printing
Small Acts, Massive Impact
Compassion usually elicits sympathy, but action creates real change. Doing something nice for someone else isn't difficult, yet the smallest acts of kindness often leave the most significant mark. This story highlights how custom 3D printing services and a few dedicated engineers helped a family in Illinois. Eureka residents Logan and Kara were raising twins, Beau and Brooklyn. Born at just 28 weeks, Beau weighed a mere one pound and eleven ounces. He needed an oxygen tank by his side at all times.
The Bottleneck: Engineering a Custom Bracket Solution
Logan faced a unique mechanical challenge. He needed someone to design and manufacture a lightweight oxygen tank bracket for Beau’s Radio Flyer wagon. The request traveled through a fascinating network. Rick Willardson, then president of the North American Society for the Advancement of Material and Process Engineering (SAMPE), heard about the situation from a former colleague. Rick posted a video on the SAMPE forum seeking assistance. Chantelle, one of our sharp engineers at NW Rapid Manufacturing, spotted the video. Moved by the request, she immediately shared it with our owner, Heather, and our resident engineering guru, Ken.
The Solution: Iterative Design and Nylon 12 Strength
Ken readily admits that stories about kids and pets hit him right in the ticker. He joked that the situation struck a C minor chord in his heart. After shedding a few entirely manly tears, the team got straight to work. Ken designed two versions of the custom 3D printed bracket. The first SLS rapid prototype lacked the necessary strength and proved a bit too flexible for real-world wagon adventures. Ken quickly pivoted to a second, far more stable design. Both iterations were manufactured using our durable Nylon powder, a material perfectly suited for strong, functional end-use parts.
The Results: The Ripple Effect of Selective Laser Sintering
Beau’s new bracket worked flawlessly. Seeing this success, Logan wanted to help other families navigate similar challenges. He connected with Advanced Ag Concepts to expand the project. Together, they manufactured five additional brackets. These robust parts were seamlessly fitted onto five Pathfinder Wagons generously donated by Radio Flyer. What started as two parents trying to improve their son’s daily life blossomed into a wider community effort. The way these connections align is genuinely awe-inspiring. We were incredibly fortunate to play a role in making this young man's life a little brighter and infinitely more mobile.
Bringing the Design to Life Through SLS 3D Printing
Have you ever wondered what happens after the lasers finish fusing the material? Cameron, our Selective Laser Sintering operator, handles the highly satisfying process of breaking the finished bracket out of the build volume. We lovingly refer to this block of unsintered material as the "cake." Once we extract the freshly printed design, we brush away the excess powder. We can recycle and reuse this remaining material for future projects, making the entire manufacturing process highly efficient.
Ready for Your Next Project?
Whether you need a heartwarming custom SLS manufacturing solution or industrial-grade rapid prototyping, we have the technology and the expertise to make it happen. Reach out to our team for more information, or upload your CAD file today to request a custom 3D printing quote.