Case Study: PAPA Pumps achieves 80–90% lower manufacturing costs and rapid design validation with 3D Systems SLS

University of Exeter uses SLS technology and DuraForm material to help PAPA Pumps explore new design, material, and manufacturing options

PAPA Pumps, a small Cornwall-based maker of water-powered agricultural pumps, wanted a durable plastic version of its traditionally machined bronze and stainless-steel products to cut manufacturing and shipping costs and open new markets. The company partnered with the University of Exeter’s School of Engineering and Computer Science to refine the design for plastic production and to create testable prototypes; because the university did not own an SLS system, parts were produced by 3D Systems using DuraForm nylon.

Using SLS prototyping allowed rapid iteration and real-world testing (including operation under pressures up to 150 psi), leading to a design optimized for injection molding. The plastic pump proved robust and can be manufactured far more cheaply—roughly 80–90% lower unit cost (injection molding estimated at 1/10–1/20 the cost of machining/casting metal)—enabling mass production and wider global markets; the project also prompted the University of Exeter to acquire its own SLS system for future work.

PAPA Pumps

Michael Burton

Managing Director