Behind the scenes: How Ultimaker 3D printers are manufactured

Quality and efficiency across processes

Components that make up Ultimaker 3D printers are delivered to our inbound quality control department, where a sample from each shipment is measured and tested to ensure they reach our standards. Parts are mainly sourced from Europe, but some specifically manufactured parts, such as stepper motors, are sourced from China.

Axle shafts are one example: these are tested for consistency with a dial caliper. If the shaft is ‘out of round’ or bowed, a dial caliper will register it and the part will be rejected. If there are too many rejected parts in a sample, the entire shipment is returned.

After testing, shipments are sorted and stored. When parts are needed on the production floor, a centralized system will generate a picklist. Part pickers use a scanner to log each item as picked, and it is automatically deducted from the main inventory.

Assembling an Ultimaker 3D printer begins with a set of panels that make up the frame. Each panel is populated with bearings, nuts, and inserts before assembly.

Each step in the manufacturing process is logged on a centralized system, which feeds back data on the ‘first time right’ of each production step. This helps to identify production bottlenecks that can be improved in order to keep efficiency at a maximum.

Assembled frames must sit completely level on a flat surface and be free of any cosmetic defects. When approved, they proceed to the main production area, where they are populated with parts such as feeders, print heads, and heated beds. The main production area is completely ESD-safe in order to avoid damage to any internal electronic components.

One method we use to keep production efficient is poka-yoke – a method that minimizes human error. Each part that makes up a printer is placed in a foam inlay pocket that will only fit a specific part. Through this, workers can identify missing parts through a quick visual inspection. There is also less chance of confusing similar parts; different lengths of axle shaft, for example, will only fit in their designated pocket.

Foam inlays are stacked in crates in order of assembly, with the top layer first. All the parts in the top layer must be fitted into the printer before the next layer can start, so that assembly is smooth and uninterrupted.

Around 400 sliding block assemblies are produced daily. These consist of two separate plastic pieces that are clamped together over a sintered bushing, timing belt, and spring, before fitting into the printer to drive the print head. Producing these assemblies was once performed by hand, but with the help of a 3D printed jig fitted to a press, labor is dramatically easier and more productive.

Print core assembly and testing

Print cores are assembled by hand and then put in a press to be sealed. There are designated stations for AA, BB, and CC print cores, with a quality inspection stage at the end.

Tested for safety and performance

We take safety very seriously at Ultimaker. All of our printers are compliant with international safety standards and regulations. As the Ultimaker S5 has an integrated power supply, it must be tested for electrical safety through a process known as ‘hipot’ testing. This ensures it is properly electrically isolated and safe to use.

All printers are XY calibrated for AA-AA and AA-AB print core combinations, so that they can dual-extrude reliably out of the box. Wi-Fi and camera modules are also tested to ensure they reach customers in a fully-functional state.

With safety and performance tested and approved, printers are packaged and stored before shipping through our global sales and distribution network.

Ready to print your next big idea?

The Ultimaker S5 is ready for serious manufacturing applications. You’ve seen how it’s produced, so why not discover what it can produce for you by clicking the link below.