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Robotics and automation systems are becoming increasingly complex—yet the market demand is trending in the opposite direction: lighter, more modular, more reliable machines with drastically shorter development cycles . To meet these pressures, engineering teams are turning toward digital manufacturing workflows, especially industrial 3D printing , to rethink how robotic components are designed and built. One of the most powerful tools unlocked by additive manufacturing is part consolidation . This design strategy—reducing multi-component assemblies into fewer, multifunctional parts—transforms traditional robotics engineering by enabling faster iteration, reduced supply chain dependencies, and more robust machines suited for demanding industrial environments. This article explores how part consolidation benefits robotics design, how it supports module-based engineering  and reconfigurable manufacturing systems (RMS) , and how Tempus 3D helps robotics companies accelerate development using HP Multi Jet Fusion (MJF) technology Why Part Consolidation Matters in Robotics Robots and automated machinery rely on high-performance subsystems such as: Actuation housings Cable-routing channels Sensor mounts End-effectors and grippers Brackets and structural supports Gearbox and motor interfaces Pneumatic and vacuum pathways Traditionally, these assemblies may require machined aluminum, multiple brackets, fasteners, weldments, and purchased components , each introducing cost, lead time, tolerance stack-up, and potential failure points. Part consolidation solves these pain points by: 1. Eliminating multi-component assemblies 3D printing allows engineers to merge several components into a single part, reducing: Assembly time Fastener count Alignment issues Maintenance complexity 2. Reducing weight while improving stiffness Light weighting is critical for robotic arms, drones, and mobile platforms. HP MJF materials like Nylon PA12 offer high strength-to-weight ratios, enabling rigid parts without excess mass. 3. Improving reliability Fewer joints and interfaces mean fewer risks of: Loosening during vibration Sensor drift Moisture ingress Cable wear 4. Enabling more compact, integrated mechanisms 3D printing allows internal channels, snap fits, lattice structures, and complex geometry that are impossible or expensive with CNC or injection molding. 5. Accelerating design cycles Robotics companies iterate constantly. Additive manufacturing enables: Functional prototypes within days Rapid design-of-experiment (DOE) cycles Immediate implementation of improvements Module-Based Design for Robotics and Automation Modern robotics manufacturers are shifting toward module-based machine architectures —standardized building blocks that can be combined or reconfigured for different tasks. Examples include: Swappable gripper modules Reconfigurable end-of-arm tooling (EOAT) Sensor or vision-system pods Universal actuator or drive modules Interchangeable robotic “stations” for automation cells These platforms demand fast customization , short tooling lead times , and cost-effective low-volume production —areas where conventional manufacturing is slow and expensive. Additive manufacturing directly supports module-based robotics by enabling: Fast customization of module interfaces 3D printing allows quick adjustments to mounting geometry, connectors, airflow channels, or wiring pathways. Cost-effective small-batch production Modules that sell in batches of 10, 25, or 100 are expensive to injection-mold but perfect for MJF. Easy scaling and versioning Robotics companies often need: V1.0 for internal validation V1.1 for pilot deployments V2.0 for customer releaseAdditive manufacturing removes tooling constraints—each version can be updated instantly. Integrated functionality Modules can integrate: Cable routing Sensor pockets Cooling channels Structural ribs Embedded fastener seats All in one print job. Reconfigurable Manufacturing Systems (RMS): A Perfect Fit for 3D Printing Reconfigurable manufacturing systems require machinery that can be quickly changed, scaled, or adapted  to new products or throughput requirements. Robotics is central to RMS—and 3D printing is what makes reconfigurability practical. 3D printing enables RMS principles by: 1. Making machine adaptations faster and cheaper Need a new bracket, sensor mount, or robot-cell fixture? It can be designed in the morning and printed by evening. 2. Supporting tooling that evolves with the product As workpieces change, 3D-printed tooling can evolve instantly. 3. Allowing custom geometry for edge-case scenarios Custom nests, fixtures, EOAT, and alignment features can be made for one-off or short-run applications. 4. Unlocking distributed, on-demand manufacturing Tempus 3D’s digital manufacturing platform allows robotics companies to print locally in Canada or ship across North America with consistent quality.HP - Optimized Drill Extraction Shoe Case Study 1: HP – Optimized Drill Extraction Shoe Example of complex internal geometry & load-bearing consolidation HP engineers re-designed a drill extraction shoe that originally required multiple machined parts. By consolidating the components into a single 3D-printed PA12 structure, they achieved: Lower weight  for reduced operator fatigue Improved chip evacuation  through internal channels Higher durability and reliability Fewer failure modes due to reduced assembly points Relevance to robotics: The same principles apply when creating robotic EOAT, end-effector substructures, or integrated cooling and pneumatic housings. Case Study 2: Aerosport – Redesigning a Rudder Trim System Example of improved performance through geometric freedom Aerosport leveraged industrial 3D printing to redesign a rudder trim system, taking advantage of: Integrated mounting features Lightweight structures Reduced part count Improved aerodynamic flow Relevance to robotics: Similar redesign strategies are common when developing lightweight robotic joints, drone components, or modular automation hardware requiring precise alignment and integrated functionality. How Tempus 3D Supports Robotics Manufacturers Tempus 3D works directly with robotics and automation companies across Canada and the U.S. to deliver: ✔ Fast, iterative prototyping Turnaround in as little as 3-5 days. ✔ Canadian, IP-protected manufacturing Keep your intellectual property safe while benefiting from fast lead times, consistent quality, and Canadian-based manufacturing you can trust. ✔ Design-for-additive (DfAM) guidance We help engineers identify consolidation opportunities, reduce weight, and improve manufacturability. ✔ Low-volume and bridge production Perfect for modular machinery and RMS solutions. ✔ Digital inventory & on-demand manufacturing Scale as needed—no tooling, no storage, no obsolescence. Conclusion Part consolidation through additive manufacturing offers robotics companies a powerful way to reduce complexity, improve performance, and accelerate development. When combined with module-based design and reconfigurable manufacturing principles, the impact becomes transformative—faster iterations, more adaptable machinery, and more competitive automation systems. Tempus 3D provides the tools, expertise, and production capacity to help robotics manufacturers bring these advantages to life.

Over the past decade, 3D printing has evolved from a rapid prototyping tool into a full-scale manufacturing technology, thanks to innovations in materials like nylon. Among the family of engineering-grade nylons, Nylon PA12  has become the most widely adopted material for industrial 3D printing , particularly with HP Multi Jet Fusion (MJF)   technology. Its excellent balance of strength, dimensional stability, and durability make it ideal for high-performance, production-grade parts. While Nylon PA11  and Nylon PA12  share similar chemistry, their subtle molecular differences lead to distinct material behaviors — and for most end-use manufacturing, PA12 offers a more consistent, versatile, and cost-effective solution . HP Multi Jet Fusion 3D printing technology. About Nylon .Nylons are a family of polyamides made by combining carbon-based compounds under high temperature and pressure. The resulting polymer chains give nylon its hallmark strength, flexibility, and long-term resilience. The numbers following “PA” (Polyamide) — such as PA11 and PA12 — indicate the number of carbon atoms in their monomer chain. This small variation creates meaningful differences in performance, processing, and application. Nylon PA11 and Nylon PA12: Key Differences Chemically similar yet functionally distinct, Nylon PA12  and Nylon PA11  perform differently under industrial conditions: Nylon PA12 is a synthetic polyamide  derived from petroleum feedstock, offering exceptional consistency and stability  in production. It exhibits superior dimensional accuracy , low moisture absorption , and excellent chemical resistance , making it ideal for parts that demand tight tolerances and reliable performance over time. Nylon PA11 produced from renewable castor oil, is valued for its sustainability and slightly higher elasticity. However, it can be more variable in mechanical performance, less dimensionally stable, and more expensive to produce than PA12. Advantages of Nylon PA12 for HP Multi Jet Fusion Nylon PA12  is the gold standard for HP’s MJF technology and remains the most commonly used nylon powder for industrial 3D printing. Its exceptional properties include: Excellent chemical resistance  to oils, fuels, grease, solvents, salts, and water High dimensional accuracy  and low water absorption , ensuring stability even in humid environments Outstanding wear and abrasion resistance , ideal for mechanically stressed parts Temperature stability  across a wide range, performing reliably even in freezing conditions Smooth surface finish  and fine detail resolution, reducing post-processing time Proven long-term durability , suitable for demanding applications across medical, aerospace, and automotive industries These attributes make PA12 a true workhorse material — perfect for functional prototypes , end-use components , and production-grade assemblies . When to Use Nylon PA11 Nylon PA11  still has its place, particularly when flexibility, impact resistance, or biobased sourcing is the top priority. It performs well in applications that require ductility, such as living hinges or moving parts. However, its higher material cost and slightly lower stiffness make it less common for large-scale production where repeatability and precision are essential. Conclusion Both PA11 and PA12 are high-performance nylons well-suited for 3D printing — but PA12 stands out as the most versatile and reliable option for industrial manufacturing . Its excellent balance of strength, accuracy, chemical resistance, and long-term stability make it the clear choice for businesses seeking consistent, production-ready parts from HP Multi Jet Fusion systems. Whether you’re developing functional prototypes or producing end-use components, Nylon PA12 delivers the best combination of performance, quality, and scalability  for modern additive manufacturing Ready for your next project? To learn more about the material properties and end-use applications of nylon and other engineering-grade 3D printing plastics which are 3D printed with HP Multi Jet Fusion technology, check out Tempus 3D’s materials comparison page . If you are ready to create your next project, visit our online quote and ordering page for pricing and ordering details. . Tempus 3D is a Canadian 3D printing service bureau which specializes in manufacturing affordable, high-quality engineering-grade plastics using industry-leading HP Multi Jet Fusion 3D printing technology. Sources: www.hp.com/us-en/printers/3d-printers/products/multi-jet-technology.html, www.weerg.com/guides/nylon-pa-11-vs-pa-12. Images courtesy of HP.

Manufacturing end-use plastic parts with 3D printing technology is increasingly common as the materials and technologies become more advanced. High-performance coatings such as Cerakote are also becoming increasingly popular to improve the aesthetics and performance of the parts. Although powder coat is not commonly used on plastic, it is a familiar finish that can be an excellent baseline to use as a comparison for those who have not tried Cerakote before. What is Cerakote? Cerakote is a thin-film ceramic coating developed by NIC industries . Originally used on metal for military applications, Cerakote is becoming increasingly popular to improve the looks and performance of 3D printed plastic parts. Cerakote extremely durable and it can increase wear resistance, corrosion resistance, chemical resistance, and hardness of the base material. Cerakote is applied as a paint, then air dried or heat-cured to chemically bond it to the surface of the part. Cerakote is a very thin compared to powder coat, with minimal effect on the dimensions of the coated part. What is Powder Coating? Powder coating is a finishing process in which dry powder material is applied to a surface, then heat-treated to create a hard coating. Powder coating can provide both functional and decorative surface coatings in a range of finishes and textures that are not as achievable by liquid coating methods. Cerakote Advantages and Disadvantages Advantages Very thin, with a thickness of approximately 0.002”. Suitable for applications with a low dimensional tolerance. High abrasion resistance. Stable in UV light. Resistant to chemicals and fluids. High resistance to flaking and peeling. a Taber abrasion test on Cerakote H-146 Graphite Black, Cerakote lasted nearly twice as long as the nearest competitive finish and 24 times as long as the furthest competitive finish. Disadvantages More expensive than powder coating. Not the best choice if a thick or textured finish is desired. Powder Coating Advantages and Disadvantages Advantages Lower cost than Cerakote. Provides a thicker finish, if this is what is desired. Disadvantages Generally not used for plastics, due to the heat-curing process. Prone to chipping or peeling. Colors can be faded by UV light. Conclusion Overall, Cerakote and Powder coat are both excellent finishes and useful to enhance the performance, durability and looks of your end-use parts. When compared to powder coat, Cerakote is thinner, more resistant to chipping and scratching, and more stable in UV light. Cerakote also has excellent resistance to chemicals and liquids. When choosing a finish for plastic parts Cerakote is generally the finish of choice, as it is specifically formulated for a variety of plastics. Tempus 3D provides on-demand manufacturing of high-performance 3D printed plastic parts for Canada's innovators. Tempus offers a variety of plastic finishing options including Cerakote ceramic coating. To learn more about Cerakote for 3D printed plastics visit www.tempus3d.com/cerakote-finish-for-3d-printed-parts .

Pilot episode of Fix it in post our interview series where we discuss manufacturing and product design. In this eopisode we have Jonathan Guercio a designer who is working with generative tools to create FPV drones. You can find him on Instagram https://www.instagram.com/jonathansdigitalcraftsmanship/ Jonathan, a graduate of the Digital Fabrication and Design course at Selkirk College and former employee of Autodesk , discusses his experiences with generative design in Fusion 360. He focuses on how it enabled him to improve the design of his FPV drone. Tempus 3D  is an HP Certified 3D Printing service bureau located in British Columbia, Canada. Tempus offers 3D printing services using HP MJF  technology, Sinterit  SLS technology, and Formlabs  3D printing technology to offer Nylon PA 12S, TPU, and a wide variety of resins including clear resin in house. Tempus serves clients across Canada and the US, and has next day shipping to most locations in Western Canada and the Pacific Northwest including Vancouver, Calgary, Edmonton, Kelowna, Victoria, Spokane, Seattle, and Portland.

Our Client Justin lost his thumb in a water sports accident. In this video we discuss the prosthetic we made for him designed by ProstheticDesignLab . After proving out the design with a home FDM printer, he came to us to have one professionally built with high strength Nylon and flexible TPU. We Used PA12S enabled by Arkema printed on our HP MJF 5200 with a dyed and vapour smoothed finish, the TPU was Formlabs TPU 90A printed on a Sinterit LISA X. Justin was able to repurpose his apple watch straps to also hold the prostetic. Quoute from Justin " I lost my thumb when my thumb was caught in the bite of a rope Foil Wake Surfing. Over the next year of healing I was in the process of trying to qualify for a prosthetic. I was denied a prosthetic from both of my insurance companies because I did not suffer enough loss of my thumb or any additional fingers. I begrudgingly accepted the decisions after lengthy appeals and had a surgery on my thumb to help relieve some of the pain.  I chose not to pay over $30,000 for a thumb prosthetic and got on with my life, adapted quickly and put it all behind me the best I could so I could move on. Just this year I got my 77 year old Father into VR Golf and gaming and started gaming the best I could but it was difficult to shoot Zombies and reload so I went looking for a solution. I found a 3D thumb prosthetic print file on Etsy for $30 very similar to the prosthetic that I had hoped for. I knew that hobby printers would be ok to start but was wanting a more refined print.  I found Tempus 3D online locally so I reached out and they brought the 3D thumb prosthetic to life. Jordan at Tempus 3D did a a fantastic job working with me to get the best materials to print the different parts for functionality and Comfort. I am proud to say that many Zombies have died since the making of my thumb and it amazes me still that we were able to take something from a web page online and replicate it in real life in front of me. What an amazing time to enjoy life!! Thank you Tempus 3D for helping improve my quality of life!! Justin " Transcript "Our Client Justin lost his thumb in a water sports accident. Unfortunately he was denied Insurance by both of his providers for not losing enough of his thumb. at the time, the cost of a prosthetic thumb was around $30 000, he decided not to pursue a prosthetic and adapted to life without his thumb. When his father got into video gaming, Justin found that he couldn't properly use the joysticks and thumb buttons. After some online searching, he found a 3d printable file on Etsy by ProstheticDesignLab After proving out the design with a home FDM printer, he came to us to have one professionally built with high strength Nylon and flexible TPU The mobility of the prosthetic was very noticeably improved. allowing Justin to comfortably play video games again and spend quality time with his father. We love to see our parts improve people lives, that's why we work with multiple prosthetics and orthotic manufacturers across Canada, speeding up production and reducing waste compared to traditional manufacturing. for more stories like these, like, subscribe, and check us out at tempus3d.com " Tempus 3D  is an HP Certified 3D Printing service bureau located in British Columbia, Canada. Tempus offers 3D printing services using HP MJF  technology, Sinterit  SLS technology, and Formlabs  3D printing technology to offer Nylon PA 12S, TPU, and a wide variety of resins including clear resin in house. Tempus serves clients across Canada and the US, and has next day shipping to most locations in Western Canada and the Pacific Northwest including Vancouver, Calgary, Edmonton, Kelowna, Victoria, Spokane, Seattle, and Portland.

In this video I give an overview of the MJF 3D printing and post produciton processeses . For this part we used Materialise Magics for slicing, HP 5200 series printer and processing station with PA12 Nylon Our modified wet media blaster A Princess Auto dry media blaster my proprietary dye system AMT Post Pro SFX vapor smoother Transcript "Hey Guys, Jordon from Tempus 3D here, I wanted to show you our manufacturing process for MJF and highlight some post production options we use right here in beautiful BC Canada. We start out in Magics which is our slicer of choice. I'm orientating the part this way for 2 major reasons, the first is that we need to allow heat to escape the prints, so ideally large holes face upward. The second reason is that with MJF printing the bottom surface will always have a better finish. Because this is a art piece that will mostly be viewed from above, I wanted that section to be facing down. There are a lot of other considerations to take into account to prevent various defects like in any type of manufacturing. Here you can see the part being extracted from the powder. The huge advantage to powder based printing is that we don't need to print any supports like in FDM or resin. We recapture most of the unused powder to be recycled back into the next build. we currently run 80% recycled powder. After the unpacking station comes the blasting, we use a modified wet media blaster to remove the bulk of the remaining powder. The advantages of wet blasting are reduced dust and longer media life. We do also dry blast the parts to get all the nooks and crannies, you can see I'm moving the gun constantly because the friction can actually burn the parts and cause damage if you arent careful. This would would be a final part if the customer chose a raw finish, but we usually dye the parts to look like this, I can't show you the dye as its a proprietary system I have designed and built inhouse. One of our newer offerings is Vapour Smoothing , we use this AMT PostPro SFX. Vapour smoothing greatly increases the finish qualtiy aswell as making the part more water and chemical resistant. For parts that are too big for our machine we borrow the capabilities of our HP partners who run much larger machines. This is a finished part with black dye and VS, it offers an even black glossy finish and a perfect base for Cerakote or paints. if you like what you see, like, subscribe, and check us out at Tempus3d.com " Tempus 3D  is an HP Certified 3D Printing service bureau located in British Columbia, Canada. Tempus offers 3D printing services using HP MJF  technology, Sinterit  SLS technology, and Formlabs  3D printing technology to offer Nylon PA 12S, TPU, and a wide variety of resins including clear resin in house. Tempus serves clients across Canada and the US, and has next day shipping to most locations in Western Canada and the Pacific Northwest including Vancouver, Calgary, Edmonton, Kelowna, Victoria, Spokane, Seattle, and Portland.

3D Printing for the Healthcare and Medical Industry The medical and healthcare industry is increasingly looking to 3D printing as an innovative way to produce tools, equipment, prosthetics, insoles, and training technology. The use of 3D printing technology for developing on-demand, custom manufacturing, is creating efficiencies in unique ways, saving both time and money, all while literally saving lives. 3D Printed Models for Healthcare and Medical Training Utilizing common medical technologies such as CT or MRI scans, 3D printing can efficiently produce precise models of organs or other body parts. These models allow surgeons, medical professionals, and patients to effectively prepare for medical procedures. 3D printed models allow for increased preparation and pre-surgery strategies, increasing the success of surgeries, while also creating patient understanding and comfort, decreasing anxiety and fear. From an economic perspective, the 3D printed modeling approach also increases the speed and efficiency of procedures, something that hospitals with limited operating rooms are increasingly interested in. Creating Medical Tools and Equipment with 3D Printing The medical industry is consistently innovating, working to find new solutions to complicated challenges. 3D printing is the perfect fit for an industry searching for custom solutions that require an iterative process. Developing medical tools, instruments, and equipment using 3D printing means prototypes can be developed at rapid speeds and they can also easily be updated and changed to suit changing needs. In an industry that deals in life and death, precision and efficiency are essential, 3D printing provides both to the medical sector. 3D Printing Custom Medical Solutions One of the greatest differentiators between 3D printing and traditional manufacturing is the ability to create custom solutions efficiently. In the medical sector, the ability to develop custom solutions will have far-reaching implications. Two clear examples of the potential impact of 3D printing can be found in prosthetics and insoles. When it comes to custom prosthetics, there are a variety of considerations to be implemented. For instance, if a child loses and limb and requires a prosthetic, they will routinely need to replace that prosthetic as they grow – this is costly and challenging for many. 3D printing can now allow these replacements to be custom-developed with greater efficiency and lower costs. Additionally, 3D printing ensures that these prosthetics perfectly fit when connecting to the patient’s body. These may seem like simple or obvious considerations, but traditional manufacturing has not allowed most individuals to receive these fully customized solutions. A more common implementation of custom medical materials is insoles. Whether you are developing a solution for a lifelong challenge or simply a corrective insole to improve posture or stride, 3D printing offers the ability to customize insoles to a patient’s needs. What would previously have required extensive moldings and processes, is now as simple as a scan and 3D printing. The precision and efficiency of this procedure serve to make insoles more readily available to those who require them. Leverage 3D printing for your own medical innovation Tempus 3D is a Canadian company providing world-class technology, services, and support to manufacturers of all sizes. We specialize in designing and producing on-demand manufacturing of industrial plastics with industry-leading 3D printing technology. One of the many industries that we are proud to serve is the healthcare or medical sector. Keep reading to learn more about how 3D printing is changing the landscape of healthcare products, parts, training, and services. Contact a member of our team to learn more about how we can support your next part or product design. To learn more about how Tempus 3D can support your next medical or healthcare project, contact us today!

If you’re looking to print strong, functional plastic parts, two of the most popular industrial 3D printing technologies are SLS (Selective Laser Sintering) and MJF (Multi Jet Fusion).  At a glance, they might look similar. Both are powder bed fusion processes and often use the same materials like Nylon PA 12. But under the surface, they work in different ways. Those differences can have a big impact on print speed, surface finish, material options, and overall part performance.  Let’s take a closer look.    How Are They Similar?  Both SLS and MJF use a powder-bed fusion process. A thin layer of powder is spread across the print bed, and only the areas that make up the part are fused. The surrounding powder remains loose, providing natural support during printing.  This approach offers several key advantages over more traditional 3D printing methods like FDM (Fused Deposition Modeling):  No support structures required  Excellent for complex geometries, including internal channels and overhangs  High level of detail and resolution  Efficient for batch production, with many parts printed at once in a single build  The main difference between the two lies in how they fuse the powder!  Sinterit Lisa X (Left) representing an SLS machine, HP MJF 5200 (Right) showing a Multi-Jet Fusion machine   SLS: Selective Laser Sintering  SLS is a well-established technology that uses a high-powered laser to scan and fuse powder particles layer by layer. After each layer is complete, the machine spreads a new layer of powder and continues building the part from the bottom up.  Strengths of SLS:  Handles complex geometries and internal features with ease  Compatible with a wide variety of materials, including flexible nylons and composites  Proven technology with a long track record in both prototyping and production  No support structures needed, allowing efficient use of build volume    MJF: Multi Jet Fusion   MJF, developed by HP, uses inkjet-style heads to deposit fusing and detailing agents onto the powder bed. After these agents are applied, an infrared heating element passes over the surface to fuse the entire layer at once.  This simultaneous layer fusion makes MJF notably faster than SLS in many applications. It also results in stronger and more consistent parts, especially in the Z-axis.  Strengths of MJF:  Also excels at complex geometries and fine features  Faster build times, especially for large batch runs  High part-to-part consistency within and across builds  Smooth surface finishes and sharp detail resolution  High powder reuse rate, which reduces material waste and production cost  Improved Z-axis strength, with more uniform mechanical properties in all directions    Which One Should You Choose?  Both technologies can produce strong, high-quality nylon parts suitable for real-world use. The better choice depends on your specific application and priorities.  Best For   SLS   MJF   Small to medium batches  Yes  Yes  High-detail, high-volume production  Slower  Faster and more consistent  Flexible or specialty materials  More options  More limited  Smooth surface finish and crisp edges  Good  Excellent  Cost efficiency at scale  Moderate powder reuse  Higher powder reuse  Complex geometries  Yes  Yes  Strong Z-axis properties  Moderate  Excellent  In short:   Choose SLS  if you're working with flexible or composite materials, or need a broader material selection for functional prototyping.  Choose MJF  if you want fast turnaround, smoother finishes, and strong, consistent mechanical properties in every direction, especially for production parts that will be under load.    Not Sure Which One to Use?  Choosing the right technology often comes down to your specific part geometry, surface finish requirements, timeline, and budget. If you're not sure which one fits your needs best, we’re happy to help.  Send us your part files or reach out with your project goals. We’ll recommend the best process to get the job done right.  Tempus 3D   is an HP Certified 3D Printing service bureau located in British Columbia, Canada. Tempus offers 3D printing services using HP MJF  technology, Sinterit  SLS technology, and Formlabs  3D printing technology to offer Nylon PA 12S, TPU, and a wide variety of resins including clear resin in house. Tempus serves clients across Canada and the US, and has next day shipping to most locations in Western Canada and the Pacific Northwest including Alberta, BC, Washington, and Oregon. Serving Vancouver, Calgary, Edmonton, Kelowna, Victoria, Spokane, Seattle, and Portland from its location in Trail, BC.

Introduction This case study walks through the step-by-step development of a generatively designed drone frame, with a focus on cutting down weight and improving structural performance. Using the high-precision HP Multi Jet Fusion 5200 printer, we refined our first prototype to strike a better balance between weight, strength, and airflow. Background The original frame was built in Autodesk Fusion 360 using its Generative Design tool, with the goal of making the chassis as strong as possible while taking advantage of the geometric flexibility that Multi Jet Fusion (MJF) 3D printing offers. While the first design turned out to be solid and stiff, it missed the mark when it came to weight savings. So, for version two, the goal shifted to dialing in meaningful weight reduction while still keeping the frame strong enough for reliable flight. Key Objectives Reduce overall frame weight without compromising strength. Distribute loads more effectively to keep flex behaviour predictable. Clean up the aerodynamics by cutting out material that messes with airflow. Analysis of Version 1.0 What Worked: Dimensional Accuracy:  All the mounting points and holes were exactly where they needed to be. Battery Holder Design:  Fit in seamlessly without causing any weird bending forces. Structural Reinforcement:  The spars connecting the arms to the battery holder helped a lot with crash protection. Aesthetic Appeal:  The frame looked good and had a clean, purposeful design. What Didn't: Too Heavy:  Despite using generative design, the frame ended up heavier than we wanted. Overbuilt Sections:  Some areas were reinforced more than needed, adding bulk without much benefit. Rear Arm Flexing:  In flight, the rear arms twisted a bit, messing with motor alignment and reducing efficiency. Blocked Airflow:  Some front structural parts were in the way of the propellers, hurting performance. Root Cause Analysis Here’s what led to the issues: Generative Design Settings:  Using the "Minimize Mass" setting led to more material being added to fight flex, which backfired on the weight-saving goal. Estimated Forces:  We based simulations on rough guesses rather than actual flight data, so we ended up over-reinforcing the frame. Post-Processing Edits:  Some manual tweaks in Blender introduced weak spots we didn’t intend. Revised Approach for Version 2.0 To fix those issues, we made a few key changes: Updated Design Objective:  Switched to "Maximize Stiffness with a Target Weight" to better balance strength and weight. Set a Clear Weight Goal:  Targeted a final weight of 12 grams, based on comparisons with other FDM-printed frames and what we learned from v1.0. Better Force Estimates:  We used more accurate force estimates that better matched real flight conditions. Implementation With those updates, we created a new generative design in Fusion 360. Here’s what came out of it: Hit the Weight Target:  The frame now weighs 12 grams—right on target. Rear Arm Improvements:  Flexing is now predictable and controlled, which helps keep flights stable. Better Aerodynamics:  Front structures were trimmed down, improving airflow around the propellers. Print-Ready Design:  The frame was optimized for Multi Jet Fusion printing, making use of the process’s ability to handle intricate details. Results and Key Findings Nailed the Weight:  The final weight came in exactly at 12 grams. Good Strength-to-Weight Ratio:  The frame kept its strength while shedding unnecessary material. Improved Flight Performance:  Controlled arm flexing led to better motor alignment and more efficient thrust. Clean Airflow:  By reducing material in the wrong spots, we boosted aerodynamic performance. Conclusion and What’s Next This project shows how refining a design through iterations—and combining that with powerful tools like generative design and Multi Jet Fusion 3D printing—can result in a highly efficient, lightweight drone frame. For the next version, we plan to use real-world flight data to make our load simulations even more accurate and explore ways to make the frame more aerodynamic and crash-resistant. Tempus 3D  is an HP Certified 3D Printing service bureau located in British Columbia, Canada. Tempus offers 3D printing services using HP MJF  technology, Sinterit  SLS technology, and Formlabs  3D printing technology to offer Nylon PA 12S, TPU, and a wide variety of resins including clear resin in house. Tempus serves clients across Canada and the US, and has next day shipping to most locations in Western Canada and the Pacific Northwest including Vancouver, Calgary, Edmonton, Kelowna, Victoria, Spokane, Seattle, and Portland.