Design innovation meets UltiMaker S6 at Aalto University

At the heart of Aalto University in Finland, the Design Factory provides students and researchers with essential tools for product development and prototyping. Whether supporting course projects, running workshops, or offering expert advice on design for manufacturing, the staff at Design Factory ensures hands-on experience is central to the learning journey.

With a full-service fab lab equipped with laser cutters, CNC tools, and a suite of 3D printers - including the UltiMaker S5, S7, and the new UltiMaker S6 - Design Factory empowers students to experiment, iterate, and bring ideas to life.

Flexible tools for a fast-paced academic environment

From semester-start prototypes to end-of-year exhibition pieces, the print queue of Design Factory’s PrintShop reflects the creative diversity of its users. Sculptor & PrintShop Master Erwin Laiho and his two colleagues manage all printing requests, ensuring students receive expert guidance throughout the process.

Speed matters, especially when we’re running against tight deadlines. The UltiMaker S6 gives us the flexibility to get an extra iteration per day - that makes a big difference.

Faster turnaround without compromising quality

Leveraging Autodesk, a recent drone component printed in PET CF is a perfect example.

This print is a bracket for a camera module and its cover plate which are attached to the bottom of the drone. Through design optimization and careful planning, the original print time was reduced from 10 hours to just 3 hours and 12 minutes on the S6. In comparison, printing the same part on the older S7 would have taken twice as long.

The print quality is as good as we could hope for from FDM.

As part of the Design Factory’s work at Aalto University, they also support start-ups - in this case by by 3D printing a PET CF nozzle prototype with the S6 for a team developing applications for sustainable biofoams.

The nozzle design included a large top opening for foam input, a smaller vent for releasing air and bubbles, and two bottom holes for extrusion. This type of rapid prototyping enables teams to quickly test and iterate on a critical machine components on campus.

Smart workflows and remote productivity

All STL files submitted by students go through a streamlined internal workflow. Using UltiMaker Digital Factory, Erwin and his team monitor, queue, and manage print jobs across the S6 and other printers - often remotely.

Digital Factory easily adds 12 hours of machine time per day

We can start prints from home, check progress, and make the most of off-hours. With just a small team, that’s a major boost.

With a mix of standard and third-party materials - such as BASF Forward AM filaments, FormFutura aluminum-look PLA, and more - the open filament system allows for maximum flexibility.

Precision and peace of mind

While data security isn’t a pressing concern, the team appreciates the reassurance of working with a European-manufactured system. Erwin explains:

Knowing where the printer comes from and how the company handles data - it gives us peace of mind.

(Prototypes of a part for one of Erwin Laiho’s sculptures printed out of white tough PLA.)

We’re responsible for the lab environment, and reliability matters.

The shift from the S7 to the S6 was smooth, and the team now relies on the S5 for large-spool jobs, while the S6 handles rapid prototyping with consistent quality. Thanks to the Material Station, Erwin and his team can keep printing continuously with peace of mind.

A partner in innovation

Through their ongoing partnership with Finnish reseller Maker3D Aalto University benefits from expert support and access to new materials.

Maker3D has been a great local partner, says Erwin. “In this field where so many aspects are digital or virtual, seeing things in practice matters - having someone nearby who understands the equipment makes a difference."

As Aalto University continues to push the boundaries of design education, the UltiMaker ecosystem plays a key role in helping students test ideas, fail faster, and succeed sooner.

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