Case Studies

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A customer approached us with a highly challenging part requiring a 0.84 mm wall thickness and a tight tolerance of ±20 microns. We submitted a quote using Tough 2000, an engineering-grade resin, and clarified that its cost is higher than standard resin. The customer noted our price was about 15% higher than a competitor’s.

After a few weeks of silence, the customer returned, requesting the same part with a glass-filled resin. We quoted using Rigid 10K, considering the demanding application. Again, the customer felt we were expensive — but since other suppliers had failed to deliver, they chose to try our solution first with Grey V5 as a trial. The initial attempt failed, but our team analyzed the issue and identified that the required wall thickness could be achieved with the right part orientation. We reprinted successfully.

Impressed by this, the customer entrusted us with a batch production run in Rigid 10K. The run succeeded, and the customer acknowledged that we were the only supplier who could technically meet the specifications, though our price was still slightly higher than those who failed to deliver.

We explained that Formlabs offers over 40 resins, each designed for specific engineering needs and price points. By understanding the application and constraints, we can provide the best-fit material and process — not just the cheapest option.

Key takeaway:

A low-cost supplier may not always solve the customer’s technical challenges. At the same time, a supplier must be fair and transparent — not opportunistic — when offering the right solution that truly addresses the customer’s pain points.

A customer approached us with a request to localise 3D printed parts in India that are currently being imported from Italy for use in machine building.

After reviewing the parts, we submitted our quote. The customer’s feedback was that our pricing was higher than their current import costs, making local sourcing unjustifiable. To address this, we proposed using Fast Model resin to minimise costs and meet their price expectations.

We produced the parts and conducted trials. Although the parts matched the required form, fit, and function initially, they began to fail under repeated loading. Further analysis revealed that the Fast Model resin had significantly lower elongation at break compared to the original material.

After several iterations, we identified Tough 2000 as the best alternative material that could meet the performance requirements. However, Tough 2000 is an engineering-grade resin that is substantially more expensive — resulting in a per-part cost nearly 2.5 to 3 times higher than the customer’s target price. Additionally, the original parts were manufactured using MJF technology, which could not be feasibly substituted with SLA in this case.

After multiple discussions, we concluded that we would not be able to meet the customer’s requirements within the desired cost constraints. We informed the customer of this decision, and they appreciated our transparency and decided to drop the localisation project.

Sometimes, saying no is the best way to uphold quality and integrity.

A start-up customer approached us with an RFP, seeking an optimised and cost-effective solution for their parts. During our review, we found that the design included wall thicknesses of less than 3 mm, with some features as thin as 1.5 mm. Initially, we proposed using mSLA technology to achieve the required precision.

However, the customer informed us that they had a very limited budget and wanted to keep trial and concept validation costs to a minimum.

To support this, we explored alternative options and suggested producing the part using FDM technology with PLA material. Since the original wall thickness was not ideal for FDM, we redesigned the part to increase the wall thickness wherever feasible, while ensuring the final dimensions met the functional requirements.

The customer appreciated our practical approach and we were able to deliver the parts within a very short lead time, successfully meeting their expectations.

Client: Medical Equipment Manufacturer
Partner: Reiva3D | Advanced Additive Manufacturing Services
Technology Used: Formlabs Form 4B & Form 4L SLA 3D Printers

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🔍 Challenge

The client’s R&D team was developing a new handheld diagnostic device for rapid point-of-care testing.
Key challenges:
• Tight timelines to prototype multiple design iterations.
• Need for biocompatible, sterilizable materials for parts in contact with patients.
• Complex internal features requiring high resolution.
• Low-volume pre-series production for clinical validation.

Traditional methods like CNC machining or injection molding were too slow and cost-prohibitive at this stage.

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⚙️ Solution Delivered by Reiva3D

✅ Rapid Prototyping with Form 4B & Form 4L
Reiva3D leveraged its in-house Formlabs Form 4B (biocompatible) and Form 4L (large-format) SLA printers to produce:
• Ergonomic enclosures and housings with fine detail using Engineering Resins.
• Functional fluid channels and sealing components with BioMed Clear Resin, ensuring sterilizability.
• Transparent covers for sensor alignment and optical testing.

✅ Quick Iterations
Multiple design tweaks were completed within few days with quick turnaround per iteration, enabling faster design validation compared to external toolmakers or generic service providers.

✅ Small-Batch Production
For initial clinical trials, Reiva3D produced limited sets of final-use components using the Form 4B. Post-processing (washing, curing, support removal) followed strict handling protocols to maintain biocompatibility.
✅ Cost Efficiency
Saved over 40% in prototyping and pre-series tooling costs, and cut development time by 30%.

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📈 Outcome
• The client reduced the time from concept to clinical pilot from 6 months to 4 months.
• The handheld diagnostic device passed usability and functional testing on schedule.
• Stakeholders used high-fidelity prototype sets for investor demos and early clinician feedback.

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🚀 How Form 4B and Form 4L Made a Difference

Form 4B: Enabled printing with BioMed resins for patient-safe, sterilizable parts.
Form 4L: Handled larger enclosures and multi-part assemblies in a single print run — increasing throughput and reducing print farm time.

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✅ Key Takeaway

Reiva3D + Formlabs Form 4 Series =
• Faster design cycles.
• High-resolution, biocompatible parts.
• Scalable bridge production.
• Regulatory-ready documentation.

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Are you exploring faster, safer ways to bring your next medical innovation to market?
Let’s talk → [www.reiva3d.com] | [Contact: +91 91485 95717 or Email: Shivakumar.Hosamani@Reiva3D.com]

Whether you want a grippy surface for functional parts, a fine matte finish for prototypes, or a custom embossed pattern for branding, PreForm’s texture mapping tools make it easy.

• Import Your Model into PreForm
• Use the Texture Tool to apply patterns like dots, grids, or custom images (BMP/PNG)
• Adjust scale, depth, and orientation for precision control
• Preview in real-time before sending to print

1. Medical Devices – Add micro-textures for better grip on surgical tools
2. Consumer Products – Give prototypes a realistic leather or fabric-like finish
3. Branding – Emboss logos or patterns directly onto product surfaces
4. Engineering Parts – Add surface roughness for paint adhesion or reduced glare

At Reiva3D, we use the Formlabs Form 4B (Biocompatible resin focus) and Form 4L (Large-format resin printer) to take full advantage of PreForm’s texture capabilities:

• Form 4B: Ideal for high-precision textured components in medical, dental, and functional prototypes
• Form 4L: Perfect for large textured surfaces or multiple parts in one go, maintaining sharp detail across the entire build

We can:
✅ Work with your existing CAD model and apply textures in PreForm without changing your original design files
✅ Suggest optimal texture types and depth for functionality and aesthetics
✅ Produce high-resolution resin prints with texture so fine, you can feel the difference

💡 From subtle tactile finishes to bold surface patterns — if you can imagine it, we can print it.
📞 Contact Reiva3D today to explore textured resin printing with Formlabs Form 4B & 4L.