3D printer helps design firm optimize products for people with disabilities

July 13, 2009
A company that develops products for people with disabilities extensively prototypes the products with a Dimension 3D printer.

Blue Sky Designs, Minneapolis, Minn., extensively prototypes the products it develops for people with disabilities. In the past, the firm used blocks of wood or other materials to determine, for instance, the length of a mechanism arm, says founder Diane Goodwin. But this approach was expensive and squelched the company’s creativity — the firm could not afford the high costs of exploring numerous concepts. Consequently, Blue Sky turned to building prototypes additively with a Dimension 3D printer.
      The 3D printer let the firm easily build several lengths and sizes of arms for end-users to try. After settling on the optimal size, the company next explored shape. The firm printed several different components, evaluating both the aesthetics and ergonomics of the prototype. This helped Bly Sky develop a device people found would work well and feel good.
      The 3D printer also let the company more easily consider factors such as manufacturability, assembly, and part costs. Initially, one new product in development included a mechanism held in place by several tiny, triangle-shaped pieces. A manufacturer quoted $0.45 to produce each piece. Blue Sky then tried printing the pieces in a “tree” form with the Dimension 3D Printer, making them into a single part. The single part cost only $0.49, thus slashing Blue Sky’s part and assembly costs. 

Watch the video...

Sponsored Recommendations

June 27, 2025
Ensure workplace safety and compliance with our comprehensive Lockout/Tagout (LOTO) Safety Training course. Learn critical procedures to prevent serious injuries.
June 27, 2025
Join our expert webinar to discover essential safety control measures and best practices for engineering a truly safe and compliant industrial environment.
June 25, 2025
An innovative aircraft with electric drives combines the best of both worlds. The cross between drone and helicopter could mean significantly faster and more efficient air emergency...
June 25, 2025
Effective when other materials fail, ceramics are particularly suitable for applications requiring wear and chemical resistance, sliding characteristics or biocompatibility. Discover...

Voice your opinion!

To join the conversation, and become an exclusive member of Machine Design, create an account today!