Case Study: Humanetics achieves rapid, cost-saving crash-test dummy development with 3D Systems' ProJet CJP

3D printing is an essential tool for continuous innovation at Humanetics

Humanetics Innovative Solutions, a 40‑year leader in designing anthropomorphic test devices (ATDs) for automotive, aerospace and defense customers, faced an urgent Department of Defense request for a highly segmented, sensor‑laden head model. Traditional prototyping with aluminum molds would have taken months and made revisions impractical, so the company needed a faster, affordable way to produce complex parts and iterate quickly.

Humanetics adopted 3D Systems’ ProJet Color Jet Printer to print patterns and mold boxes overnight, enabling silicone molds and urethane parts the next day. The approach cut prototype turnaround from weeks or months to about a day and a half for parts, yielded roughly 10:1 savings in materials and machining (hundreds of dollars per build), supports about 200 parts a year and improved both development speed and communication with customers.

Humanetics

Kris Sullenberger

Project Engineer