Bringing Small Part Production In-House with Carbon Fibre 3D Printing

How we replaced an outsourced steel component with in-house additive manufacturing at the Forma 3D Print Lab

After dealing with ongoing delays and quality issues from an external supplier, we made the call to bring production of one of our steel components in-house using additive manufacturing. The part had been used on one the 70 Series Barn Door Tables, developed by our sister company Overland Tourers Australia (OTA). It had become a bit of a headache - timelines were slipping, costs were going up, and the inconsistency was starting to show.

Switching to local, in-house production at the Forma 3D Print Lab gave us the chance to take control of the process and improve how we build. On-demand 3D printing meant we could react faster, reduce reliance on external suppliers, and keep quality where it belongs - with us.

The Problem

We’d been outsourcing the part for a while, but between long lead times, inconsistent finishes, and supplier communication gaps, it was starting to impact more than just production. It was a small part, but an important one - and delays here had a knock-on effect.

Rather than continuing to chase fixes, we looked at how we could make the part ourselves using the gear we had in-house.

The Approach

We got stuck into CAD development based on what the part needed to do and how it was being used. The updated design was prepped for continuous carbon fibre (CCF) printing using our Markforged Mark Two, which gave us strength and reliability that stacked up well against the original steel.

We also took the opportunity to simplify things - reducing the number of hardware components and making the assembly process faster and more consistent.

Testing and Fitment

Once the first version was printed, we ran it through testing to make sure it aligned properly and did its job. The material held up exactly as expected, and the fit was spot on. No need for revisions, which meant we could move straight into repeatable production without delay.

The Outcome

Since switching to the new CCF version, we’ve tightened up turnaround times, removed an ongoing supply issue, and made the install process easier. It’s lighter, local, and gives us full control over quality and delivery - without relying on third parties.

Need to solve a supply issue or bring a small part in-house?

Contact our friendly team today!

Address: 11 Mort St, Newtown 4350 QLD
Email: admin@forma3d.com.au
Phone: (07) 4588 6659