Case Study: Hänssler Kunststoff- und Dichtungstechnik GmbH prints a full-scale kayak with Aibuild CAM

Hänssler Kunststoff- Und Dichtungstechnik GmbH prints a full-scale kayak in 33 hours with Ai Build

Hänssler Kunststoff- Und Dichtungstechnik GmbH, a German plastics and sealing technology specialist, sought to test the limits of large format additive manufacturing (LFAM) and prove out a new production process for complex, functional parts. The company used Ai Build's software, Ai Build CAM, to design and print a full-scale kayak as a functional prototype, moving directly from a digital design to a physical part without the dedicated tooling required by conventional methods.

Using Ai Build CAM, Hänssler printed the kayak in two halves from a glass-fibre-reinforced polypropylene, which were then welded together. The solution allowed for functional features like tool pockets to be built directly into the print, eliminating separate assembly steps. The final part was printed by Ai Build in approximately 33 hours, measuring 2856mm long and weighing 20kg, successfully demonstrating a viable and efficient path for small batch production that offers significant cost and lead time advantages over traditional blow moulding or centrifugal casting.

Hänssler Kunststoff- Und Dichtungstechnik GmbH