Case Study: 3D Systems achieves a 55% lighter, structurally efficient 3D-printed skateboard with Altair's solidThinking Inspire

3D Systems - Customer Case Study

3D Systems, a pioneer in 3D printing, was tasked by the Cooper Hewitt – Smithsonian Design Museum to design and 3D print a structurally sound, lightweight skateboard. To meet this challenge they used Altair’s solidThinking Inspire to explore topology-optimized concepts and drive the design process.

Using Altair’s solidThinking Inspire, 3D Systems generated 20–30 optimized concepts, refined the winning deck and truck shapes in CAD, and produced the parts—PA‑12 nylon deck via SLS and titanium trucks via Direct Metal Printing. The resulting skateboard assembly weighs 3.4 pounds, roughly 55% lighter than a standard board, was displayed at the Cooper Hewitt, and demonstrated clear, measurable benefits from Altair’s optimization tool.

3D Systems

Seth Astle

Senior Industrial Designer