Case Study: American Precision Prototyping achieves 30-day production of 150 POWERADE World Cup bottle carriers with 3D Systems' SLA 3D printing

American Precision Prototyping - Customer Case Study

American Precision Prototyping (APP) was contracted by The Coca‑Cola Company to redesign, prototype, cast, decorate and ship 150 six‑bottle POWERADE carriers for the 2014 FIFA World Cup — all on a 30‑day timeline. The team had to combine ergonomics from previous designs into a new two‑half snap‑fit carrier and get rapid customer approval before moving to production.

APP used CAD and 3D Systems SLA printing to produce a half‑scale prototype and multiple full‑scale mold masters (six masters printed in days), then created RTV silicone molds and cast parts in impact‑resistant InnoTuf TP‑4050 urethane. The team manufactured 300 carrier halves with minimal post‑processing, decorated each unit with vinyl decals, ran round‑the‑clock shifts to meet demand, and delivered 150 finished carriers with days to spare while maintaining tight tolerances and production quality.

American Precision Prototyping

Jason Dickman

President