Case Study: Decathlon achieves 80% faster print preparation and 100‑part high-density batch production with 3D Systems' Figure 4 and 3D Sprint

High Density Stacking Capability Drives Productivity in End-Use 3D Part Production at Decathlon

Decathlon, the world’s largest sporting goods retailer, needed a cost-effective way to produce a small mould-injection part for shooting/safety glasses without expensive tooling. To validate additive manufacturing for batch production, its ADDLAB tested 3D Systems’ high-speed Figure 4 platform together with the new high-density stacking feature in 3D Sprint to see if direct 3D-printed end-use parts could meet productivity and quality requirements.

Using 3D Sprint’s stacking tools and Figure 4 with PRO-BLK 10 material, Decathlon now prints batches of 100 parts in about 85 minutes (~42 seconds per part), cut print preparation from 30–60 minutes to 6–10 minutes (≈80% time savings), and achieved batch post-processing efficiencies (6 min cleaning, 90 min cure, 10 min support removal for 100 parts). The solution delivered reproducible, production-grade parts and enabled direct digital production that replaces costly injection molding.

Decathlon

Gregoire Mercusot

Materials Engineer