Ultimaker uses functional, analytical and tracking cookies. Tracking cookies enhance your experience on our website and may also collect your personal data outside of Ultimaker websites. If you agree with the use of tracking cookies, click “I agree, continue browsing”. You can withdraw your consent at any time. If you do not consent with the use of tracking cookies, click “Refuse”. You can find more information about cookies on our Privacy and Cookie Policy page.
Idea Reality: Rapid prototyping and the art of failing forward
Adam Kohut
Product development
Product development, and especially prototyping, is no easy game. By nature, it requires iterations, mistakes – even failures – with each misstep offering the opportunity to tweak, refine, and perfect.
This process, however, is traditionally costly. It sucks up time. It drains bank accounts. And while 'failure' in product development is to be expected, costs still add up. That’s why Idea Reality, a Hampshire, England-based product design and development studio, has turned to 3D printing.
Let’s iterate
“[The technology has shown us] a substantial improvement, not only in terms of what we’re able to achieve in the time and the cost, but also the benefit to our customers,” James Lamb, Idea Reality’s Design Director, said. “We’re finding we’re changing our initial process for prototyping for the first time. We’re doing more of a phase where we’re happy to iterate and run through a project very quickly, in one chunk of work, rather than repeatedly going back to the customer for input. This allows us to give them something that’s right first.”
Idea Reality's team of six designers is based in Hampshire, England
The bulk of Idea Reality’s clients are consumer-focused, meaning the products they eventually bring to market will be mass-produced and sold in stores. It predominantly works with individual entrepreneurs and start-ups, assisting them on the path from literal drawing board to finished product. Initial prototypes are iterated using an Ultimaker S5 printer until Idea Reality's team of six designers is satisfied the design works as well as possible. Then, in most cases, subsequent prototypes are outsourced to more closely resemble the finished product.
Most projects, James said, require between three and five iterations, depending on the product and its complexity. Many of these eventually go the route of injection-molding – an area in which 3D printing is extremely helpful, as it allows flaws and other imperfections to be spotted early in the design process, before more finalized – and expensive – steps are taken, all while using the same or similar plastics.
"The fact that we can turn around something overnight and pop [a prototype] in the post the next day is something of a game-changer," James said. "We’re able to produce things faster, with even less uncertainty and more reliability."
Cap valve prototypes created by Idea Reality
From print to product
Idea Reality’s clients, too, have seen their share of success. Take the teacher who developed a protractor for math students, then licensed it to one of the UK’s largest manufacturers of stationary for schools. Or the FlushBrush, an updated design of a toilet brush that is both more hygienic and effective – and which received funding on the popular British reality television series, “Dragon’s Den”.
An Ultimaker S5 works to create a prototype of the FlushBrush, a redesign of a traditional toilet brush which was featured on the television series "Dragon's Den"
Using the Ultimaker S5, the Idea Reality can handle more projects in a shorter timeframe. The Ultimaker’s reliability and ease of use, James said, made it a good fit for the studio – as did its open filament system, which enables Idea Reality to discover and select the perfect material for any given job, whether it’s TPU, PP, or carbon fiber-reinforced.
"We wanted to make sure that we weren’t going to be limited to the standard hard plastics," James said. "We were keen to try other materials so that we could essentially do rubberized sections or create little light pipes or things like that. That’s one of the main reasons we went with the Ultimaker, because we felt like it could grow with us."
Electronics casing prototypes
One of Idea Reality’s most recent developments, for example, was a backpack that takes the weight off the wearer’s shoulders via an ergonomic design. That meant lots of printing and lots of changes. It also meant the prototype needed to be able to withstand and adapt to near-constant fluctuations in pressure from the wearer’s movements. Based on this knowledge, Idea Reality chose a nylon material, which is known for its high impact strength and wear resistance.
Going global
With an average of 50 clients per year, which come from across the UK as well as the world – Dubai, Spain, Sweden, Australia, India – Idea Reality is gearing up for a future in which 3D printing is heavily integrated.
"With 3D printing, language is now our main barrier, not technology," James said.
Prototypes for a product sold in the cosmetics market
As that technology advances, James said, Idea Reality will look at options in printing end-use parts, undoubtedly a benefit to its industrial clients, which currently account for about 20% of its total customer base. But for now, the studio will continue designing, iterating, refining – working with failure as a means to perfection.
Yasuhide Yokoi and Final Aim Inc: Designing an autonomous delivery robot
Yasuhide Yokoi and his team at Final Aim Inc. used Ultimaker 3D printers in the creation of a new autonomous delivery robot, enabling rapid design iterations during prototyping.
Consumer goods
Product development
Old Dominion University: A student engineering makerspace that exceeds expectations
Old Dominion University uses Ultimaker 3D printers to deliver a new level of innovation and confidence for engineering students.
Education
Azoth: Driving the transformation of physical to digital inventory with additive manufacturing
Azoth builds a new business helping manufacturing customers have machine parts right on time while saving thousands of dollars.
Industrial goods
End-use parts
Manufacturing aids
NavVis: Rapid prototyping wearable scanners with 3D printing
Discover how two industrial designers at NavVis used rapid prototyping and 3D printing to validate their breakthrough design for a professional wearable indoor scanner.
Product development
Schwartz Off Road Motorsportz: Saving time on and off track
Schwartz Off Road Motorsportz uses 3D printing to replace worn out parts quickly and on a limited budget, while also being able to innovate to keep their vehicle competitive.
End-use parts
Metro Plastics: Injection mold company looks to 3D printing to solve bottlenecks
With the always-on productivity of the Ultimaker S5 Pro Bundle, Metro Plastics found a solution to their long lead times, while saving up to 90% on manufacturing parts.
Industrial goods
Manufacturing aids
End-use parts
Van Amersfoort Racing: 3D printing when every second counts
Success hasn’t stopped Van Amersfoort Racing from finding new ways to literally put it ahead of the competition. That’s why the team has begun to utilize 3D printing.
Automotive / aviation
Manufacturing aids
End-use parts
ERIKS: Working clean, certified, and in control with 3D printing
ERIKS offers technical components and related services to all sections of industry. By adding 3D printing technology to its workflow, the company is able to provide its customers with a service that holds the potential to shake up industries around the globe.
End-use parts
Industrial goods
Manufacturing aids
ZEISS: 3D printing precision parts for serial production
Carl Zeiss Optical Components uses Ultimaker printers to create adapter plates customized to its industrial microscopes and capable of serial production.
End-use parts
Industrial goods
Kootenay-Columbia Schools: 3D printers teach lessons in creativity and resilience
Kootenay-Columbia School district uses 3D printing to provide new learning opportunities, sparking creativity, imagination, and engagement across subjects and grade levels.
Education
Idea Reality: Rapid prototyping and the art of failing forward
Product design and development studio Idea Reality is using 3D printing to reduce costs and save time in bringing consumer-targeted projects to market.
Product development
Schubert: A digital warehouse for on-demand manufacturing
Schubert uses 3D printing to deliver tools for its future-proof, high-performance packaging machines, making them even more versatile and easy to operate.
Industrial goods
End-use parts
Killa Design: 3D printing the buildings of tomorrow
Killa Design uses 3D printing to create iconic designs that are fast becoming landmarks – including one of the most complex structures ever built.
Architecture
Heineken: Ensuring production continuity with 3D printing
Learn how Heineken increased line uptime and efficiency at its Seville brewery using 3D printing to create custom safety devices, tooling, and functional parts.
Consumer goods
End-use parts
Reducing costs and improving efficiency with the Ultimaker S5
IMI Precision Engineering, a leader in motion and fluid control technologies, use 3D printing to help create solutions that provide speed and precision for machinery.
Industrial goods
Enhancing patient care with 3D printing at Jefferson Health
Jefferson Health, a hospital system located in Philadelphia, is at the forefront of healthcare technology, have integrated 3D printing into their Health+ Design Lab.
Medical
3D printing custom refractory mold cores for industrial ceramics
Discover how a Czech industrial ceramics supplier benefits from Ultimaker 3D printers to create bespoke 3D printed refractory mold cores.
Industrial goods
Manufacturing aids
Ford: Reinventing efficient manufacturing using 3D printing
Ford has been working on creating an optimized workflow to create jigs, tools, and fixtures for Ford’s manufacturing process.
Automotive / aviation
Manufacturing aids
Royal Netherlands Air Force: Speeding up maintenance with 3D printed tools
The Ultimaker 3D printers help mechanics of the Royal Netherlands Air Force to speed up the maintenance of helicopters, fighter jets and large cargo planes.
Automotive / aviation
End-use parts
Transforming the face of architectural design with 3D printing at KPF
The role of physical models within the architectural design process has evolved over the past few years. At firms like Kohn Pedersen Fox (KPF) desktop 3D printers enhance the day-to-day iterations of design and the three-dimensional understanding.
Architecture
Owens Corning: Creating the perfect material profiles for customers’ solutions
To help customers get the best out of the XSTRAND™ range, Owens Corning collaborated with the engineers at Ultimaker to create optimized material profiles that are now available in Ultimaker Cura.
Industrial goods
Product development
New Lab innovators print their way to faster iterations and design freedom
In an era when startup incubators and co-working spaces spin up as a matter of course in densely populated urban centers, New Lab offers a fresh take on what it means to bring people and companies together to work under one large roof.
Product development
Producing customized fashion solutions with Ultimaker 3D printers
Florenradica is a design company fabricating prototypes and end-use parts for fashion houses. After discovering 3D printing, they were interested in exploring it further, as it allowed them to realize products that were not possible with CNC machines.
Consumer goods
Product development
BOSEbuild: Accelerating design and testing phases with 3D printed parts
Learn how BOSEbuild took advantage of Ultimaker 3D printers to quickly and seamlessly prototype their latest build-it-yourself headphones, saving time and money through in-house iterations.
Consumer goods
Product development
Make Architects: From 3D print to award-winning building
Learn how Make Architects have transformed their model-making and prototyping process thanks to a suite of Ultimaker desktop 3D printers.
Architecture
Empowering student innovation at the NYU Tandon School of Engineering
The NYU Tandon School of Engineering is more than just a resource for students who want to learn about the technology of today and tomorrow. It prepares students to be motivated and self-sufficient when tackling science and engineering issues.
Education
3D printing for product development to cut costs and save time
Hartfiel Automation is a specialized high-tech provider of pneumatics, motion, and mobile control solutions. With the addition of an Ultimaker 3D printer to their product development process, Hartfiel Automation was able to save time and money while diversifying their services with product offerings...
Industrial goods
Product development
The Ultimaker S5 is here
We are proud to announce our most advanced 3D printer yet – the Ultimaker S5. Built for the office, the Ultimaker S5 is a powerful, reliable, and versatile 3D printer that delivers industrial-class results.
3D printing prototypes to save money and minimize risk
NoiseAware, the startup behind a noise monitoring and management system for high-risk, short-term rental properties, designed and prototyped their product with their in-house Ultimaker 3 printer. Saving thousands on the initial prototyping process for all parts, the NoiseAware team is able to create...
Consumer goods
Product development
Research on the benefits of 3D printing in a trauma hospital
3D printing is seeing increasingly widespread adoption in the medical field. It has already been used to visualize bone fractures, but pioneering researchers believe it can also be used to help treat trauma patients.
Medical
3D printed puzzle breaks down braille barriers
For visually impaired people, learning to read braille is essential. But for many, braille learning devices are either too costly or ineffective. Now a 3D printed puzzle is making this vital skill accessible to all.
Education
End-use parts
A study in innovative design at the Cincinnati Art Museum
Dedicated to promoting inventive art-related exhibits and programs, the Cincinnati Art Museum is exploring the relationship between 3D printing and fashion by highlighting the work of designer Iris van Herpen.
Consumer goods
3D printing and the jewelry boutique: A model for small business success
Cameron and Rebecca Stern, co-creators of Stern Design Works, bring together their innovative approach to traditional jewelry manufacturing with a fleet of Ultimaker professional desktop 3D printers.
Consumer goods
Product development
Exploring our galaxy – and beyond – with 3D printing
With the help of 3D printing, the communication team at NASA's Chandra X-ray Observatory makes it possible for inquisitive learners of all ages to hold supernovas right in the palm of their hand.
Education
Casting metal parts for prototyping from 3D prints
Sylatech uses Ultimaker 3D printers to optimize their metal casting prototyping process. The accelerated placement of tooling orders and reduced number of tooling modifications result in significant time- and cost savings.
Industrial goods
Product development
Cost-efficient, functional prototypes for small bore motorcycle parts
With Ultimaker, MNNTHBX found a more efficient way to design and produce prototyped parts in the small bore motorcycling industry. By switching from traditional methods of manufacturing to 3D printing, the team replaced dozens of hours at the CNC mill and saw a 90% reduction in raw material cost.
Automotive / aviation
Product development
3D printing and the future of personalized fashion
For designer Jessica Joosse, the fourth industrial revolution is transforming fashion, and an Ultimaker 3D printer is the perfect tool to explore possibilities.
Consumer goods
Farmshelf: Cost-effective custom parts for an urban farm system
By using Ultimaker 2+ 3D printers, Farmshelf was able to iterate designs and print hundreds of custom parts; far more quickly than other methods of fabrication.
Consumer goods
Product development
Taking architecture from dream to design with 3D printing
3D printed architectural models do more than simply provide tangible build site plans. These 3D prints show clients how key architectural features can bring the entire design to life.
Architecture
An innovative 3D printing venture at Atlantic University College
With support from students knowledgeable in 3D modeling and CAD software, Professor Vicente Gasco has set out to send 3D printing-savvy graduates into the working world through courses featuring the latest technologies.
Education
Faulkner Industrial: 3D printing the future of architectural design
Thanks to a streamlined digital-to-physical pipeline and a reliable Ultimaker desktop 3D printer, Faulkner Industrial is able to deliver architectural scale models at a fraction of the cost and turnaround time compared to competitors.
Architecture
St. Matthew’s Episcopal Day Maker Lab: Inspiring through innovation
By providing a space for students to design, iterate, and print objects from their own imaginations, the St. Matthew’s Episcopal Day Maker Lab is able to amplify the learning experience in meaningful, impactful ways. Keep reading to learn more.
Education
Entrepreneurship at MIT Launch: 3D printing for the future
The minds behind MIT Launch understand that there are limitless possibilities for 3D printing. By challenging students and encouraging innovation through the latest technologies, Launch is preparing young minds for the challenges that lay ahead.
Education
Eram heels: 3D printing personalized shoes in-store
Have you ever been shopping for shoes and found it hard to get exactly the style you want? Now, with the help of a couple of Ultimaker 3D printers, fashion retailer Eram and Unistudio design studio are giving customers the power to create their own heels.
Consumer goods
End-use parts
Snow Business: 3D printing final parts for high-value snow machines
Snow Business is the world leader in snow and winter effects. The company uses their Ultimaker 3D printers for prototyping, functional testing, and creating final parts for their snow machines.
Industrial goods
End-use parts
Gantri: Shedding light on unique 3D printed designs
Prototyped and manufactured with an Ultimaker 2 Extended+ print farm, Gantri products celebrate traditional techniques bolstered by new technologies that save time and money for a passionate community of designers.
Consumer goods
Product development
Tucci Hot Rods: 3D printing final custom car parts
Tucci Hot Rods uses 3D printing to create custom car parts for its vehicle modification projects. The 3D printed parts can be made in a couple of hours and - after a bit of post-processing - will be used as a final part on the custom cars.
Automotive / aviation
End-use parts
Rapid design iterations for the early project stages
Honeybee Robotics is a design and engineering solutions firm known for contributions of critical planetary analysis technology to NASA’s past three Mars missions. Their designs are “destined for work on Earth, Mars, and beyond.” Their work extends to other industries as well, leveraging hard-fought...
Industrial goods
Product development
Volkswagen Autoeuropa: Maximizing production efficiency with 3D printed tools, jigs, and fixtures
Learn how Volkswagen Autoeuropa is using 3D printing to maximize assembly efficiency. By using 3D printed manufacturing aids the company reduces cycle time operation, labor, and the need for reworking, while improving tool ergonomics.
Manufacturing aids
Automotive / aviation
print+: 3D printed DIY headphones
print+ is a product line of DIY kits that allows consumers to build and customize their own headphone. As the mechanical parts can be 3D printed locally, less material needs to be shipped - reducing costs and lowering environmental impact.
Consumer goods
End-use parts
Faster, more accurate dental models
Using 3D printing technology, OpLab can quickly and easily create physical models of dental arches, reducing time, labor, and expenses in the process. The new approach means the team can achieve greater model accuracy, resulting in less error and a better service for their clients.
Medical
Cardiff University: Accessible 3D printed microfluidic devices
The 3D printed microfluidic devices developed by researchers at Cardiff University offer a cost-effective alternative to the traditional ones, which are expensive and require specialized skills and equipment.
Education
End-use parts
Rapid prototyping to solve 21st century problems
Native Union used their Ultimaker 3 to rapidly prototype parts and mechanisms for their latest device designed to resolve a common 21st century issue, making messy USB charging cables a thing of the past.
Consumer goods
Product development
3D printing in landscape architecture and pool design
3D printing is changing the face of architectural design. Discover how landscape designers are transforming outdoor spaces into memorable locations that allow people to fully engage in their surroundings, while making a positive impact on the environment.
Architecture
Open Bionics: 3D printed prosthetic limbs
Using an Ultimaker 3D printer, Open Bionics is developing tailor-made 3D printed prosthetics at a fraction of the cost of traditional ones. Read all about their remarkable story here.
Medical
3D printing in furniture design
3D printing can be used to create virtually anything. Designer Jon Christie used his Ultimaker 3D printer to create some impressive 3D printed furniture, which offers flexibility and reduced costs. Learn more here.
Consumer goods
Product development
Inholland University: Building a 3D printed rocket
Students at Inholland University of Applied Sciences use 3D printing to design and build rockets as part of their course in aviation technology. Read on and download a ready-to-use lesson plan to include 3D printing in your school's educational program.
Education
Vathorst College: Integrating 3D printing in high school education
Creative STEM projects allow students to expand their knowledge and develop basic 3D printing skills. Read on for lesson plans that focus on both science and mathematical applications.
Education
Eventuri: Functional and fit testing of performance car intakes
With 3D printing companies like Eventuri can be flexible in their design process, run quick iterations and perform functional and fit testing of their 3D printed car intakes in a short period of time.
Automotive / aviation
Product development
MATT Architecture: Rapid model making with 3D printing
MATT Architecture creates architectural models in central London. They use 3D printing to quickly reiterate the models they are working on, which saves a lot of time and development costs.
Architecture
Changing lives in developing countries with 3D printed prosthetics
The Victoria Hand Project creates customized prosthetic hands for amputees in third world countries – using Ultimaker 3D printers to make the process more efficient and cost-effective.
Medical
Using Ultimaker to cast silicone for soft robotics
Using their Ultimaker 2+ 3D printer, students from Delft University of Technology have discovered a way to cast silicone for soft robotics. This has huge implications for soft actuators, and for the medical sector. Read on to learn more.
Education
Product development
Henchmen Props: 3D printed props workshop
Henchmen Props creates props and costumes for industry-leading video game companies like Blizzard and Respawn. 3D printing has allowed them to greatly reduce their production times and rapidly prototype new parts.
Product development
Teaching STEM with 3D printed bottle rockets
There are many ways in which 3D printing can be used to enhance the students' learning experience in modern-day primary education. Discover how 3D printing can boost learning here.
Education
The Ultimaker 3: Behind the scenes
3D printers let product designers and engineers test, evaluate and improve their ideas. Even more importantly, they’re a powerful tool for various professional applications. Read on to find out how we developed the Ultimaker 3.
Product development
Bringing the Ultimaker 3 to market with bridge manufacturing
Ultimaker 3 has proven to be a reliable solution for businesses. Learn how bridge manufacturing helps you launch products on time, with a 3D printer that's primed to deliver results.
Industrial goods
End-use parts
Functional prototyping at ABB Robotics
3D printing gives businesses around the world the opportunity to save time and money. ABB Robotics turned to the Ultimaker 2 Extended+ for making prototype fingers for their robot YuMi, bringing new opportunities to the company.
Industrial goods
Product development
Breaking barriers in education with 3D printing
With a desktop 3D printer, teachers can empower their students to design, collaborate, and create amazing things they never thought possible. But what is it actually like to have a 3D printer in the classroom?
Education
From a market-tested prototype to an eye-saving game-changer
oDocs Eye Care Kit has the potential to save millions from blindness. But this wouldn’t be possible without functional prototyping. And 3D printing is the most accurate, not to mention time and cost-effective, way to achieve it.
Medical
3D-powered prototyping by the Bhold Studio
How far can you get with a dream and a 3D printer? You can think of the most sophisticated forms and textures, turn them into successful products and blaze through prototyping and production at lightning speed.
Consumer goods
Product development
Surgical planning using 3D printed bone models
Professional 3D printers are now being actively used by healthcare professionals not only to educate patients about their condition, but also to plan complex surgeries – even using the models during the operation as a guide.
Medical
3D printing a Tyrannosaurus rex skeleton
To build a 13 meter long T. rex skeleton, Naturalis turned to 3D printing. Thanks to the incredible accuracy and flexibility of the Ultimaker 2+, the skeleton will be restored in even greater detail than initially anticipated.
Education
Developing sustainable fuel with Team FAST
Using their Ultimaker 3D printer, Team FAST was able to design and print custom mounts and fittings for their car prototype fueled with formic acid.
Education
Using 3D printed shapes to create food molds
3D printing shapes and prototypes for food-safe molds is becoming a popular 3D printer application in the food industry that allows entrepreneurs to escape the demands of industrial-sized production runs.
Consumer goods
Product development
Saving eyesight with a 3D printed eye examination kit
oDocs Eye Care creates open source medical equipment for eye diagnoses. Using 3D printing, they developed a cost-effective and accurate eye examination kit to help diagnose treatable and preventable blindness.
Medical
End-use parts
Using Ultimaker 3D printers for manufacturing at Siemens
Learn how Siemens Rail Automation are using their Ultimaker 3D printers to assist in prototyping of new components and products, as well as manufacturing end-use parts.
Industrial goods
Product development
Project Seafood, creating waves of change on our shores
Desktop 3D printing allows anyone to transform ideas into tangible products in a matter of hours. This is a story of a couple who took their Ultimaker Original out for a spin in their mini-van to make a better world.
Product development
Architects use 3D printing to prototype huge city project
To help bring their ideas to life Sweco architects needed a rapid prototyping tool they could rely on every day to create models with tight deadlines. So they turned to 3D printing.
Architecture
The Olsson Block - a community invention by Anders Olsson
We're proud to say that an essential part of the Ultimaker DNA is our strong community. we’d like to highlight the work of an ingenious community member called Anders Olsson, the man who gave us the Olsson block.
Education
Product development
The world's fastest 3D printed R/C car
What do you do when you want to build the world's fastest radio controlled car? Build it yourself! Read this story to find out how one man designed and created a 3D printed RC car from scratch.
Product development
3D printing in education for inspirational learning
More and more, 3D printing is being used in education. Teachers use 3D objects to help primary school kids grasp concepts, refine students' creative skills in high school and help them learn technical subjects at university.
Education
100% recycled filament from Perpetual Plastic Project
At this moment there are huge amounts of waste plastic, and only 10 to 12% of it is being recycled. The team behind the Perpetual Plastic Project is looking to change the world by reducing the amount of plastic.
Consumer goods
Product development
Meet Luke and his 3D printed e-NABLE hand
With a global network of over 5,000 volunteers, the e-NABLE foundation designs, creates, and donates their 3D printed hands free of charge to children and adults using Ultimaker 3D printers.
Medical
3D printed and prototyped shoes by Julian Hakes
Learn how fashion designer Julian Hakes brought his award-winning Mojito Shoe to life. With his Ultimaker 3D printer, he was able to create multiple prototypes in-house and perfect his designs.
