Case Study: RJ Studios cuts time-to-market 20% and adds sculptural detail to CAD models with 3D Systems' Geomagic Freeform

RJ Studios Uses Geomagic Freeform to Save Time and Add Detail to CAD Models

RJ Studios is a 30-person product development shop that sculpts licensed characters and engineers mechanisms for mass production for clients like Mattel and Fisher-Price. Their process used to require sculptors to spend 60–80 hours re-sculpting an approved wax model to be ~7% larger for production, effectively doubling effort and risking longer approval cycles — a major time-to-market bottleneck.

By adopting 3D Systems’ Geomagic Freeform, RJ Studios now scans approved sculpts and digitally scales or refines them in minutes, avoiding time-consuming re-sculpts and re-approvals. Freeform also exports IGES surfaces into SolidWorks (using a cavity workflow) so engineers can build internal mechanisms and prepare shells for production. The result: richer sculptural detail in CAD, smoother downstream engineering, and a 20% reduction in lead time to market.

RJ Studios

Muggs Ferguson

Director of New Technology