Case Study: Bastian Solutions achieves a next-generation, lightweight, energy-efficient Shuttle System with Fast Radius additive manufacturing

How we helped Bastian Solutions save $100,000 in production costs by delivering a customizable, next-generation materials handling robot made with additive manufacturing

Bastian Solutions, a leading materials handling company owned by Toyota Advanced Logistics, set out to build the next-generation Bastian Solutions Shuttle System — a customizable robot arm-and-shuttle that can pick a wide variety of products in tight warehouse spaces. Lacking on-site 3D printing, Bastian Solutions partnered with Fast Radius and its additive manufacturing services (including HP 3D Printing and Carbon® technologies) to manufacture complex, customer-specific parts and accelerate development.

Fast Radius produced nearly 50% of the shuttle system’s bill of materials at its Chicago factory and Virtual Warehouse, enabling rapid custom parts, lighter components (using HP Multi Jet Fusion and HP 3D HR PA 12 Glass Beads), and a unique Carbon®-printed “Shark Fin” gripper (EPU 40). As a result, Bastian Solutions designed, produced and tested hundreds of prototypes in fewer than 20 months, cut two years off development, saved $100,000 in production costs, and shortened part lead times to days — outcomes delivered through Fast Radius’ additive manufacturing platform.

Bastian Solutions

Ron Daggett

Vice President of Technology and R&D