Case Study: U.S. Architectural Lighting achieves $50,000 annual savings and faster prototype-to-cast turnaround with 3D Platform

How 3D Printing Casting Masters Saved $50,000 Annually

U.S. Architectural Lighting, a California manufacturer of over 400 standard luminaires and custom outdoor lighting solutions, needed faster, cost‑effective prototyping to meet demanding site conditions and win custom work. Previously they relied on outsourced SLA prints that cost about $50,000 a year, ran roughly $3,000 per part, and took two to three weeks or more—slowing development and adding expense.

By installing a large‑format 3D Platform FFF printer they began printing robust PLA masters for quick green‑sand aluminum casting, trimming finishing time and eliminating outside print costs. The in‑house workflow turns CAD to metal prototypes in days instead of weeks, paid for the machine within six months, saved roughly $50,000 annually, and contributed about $90,000 to the bottom line over 18 months.

U.S. Architectural Lighting

Tim Carraher

Lead Engineer