Case Study: BattleBots achieves rapid, lightweight metal 3D-printed parts and 90% cost savings with Proto3000

BattleBots® Team Uses Metal 3D Printed Parts To Create Combat Robot

BattleBots competitor Team SawBlaze faced a tight build calendar and strict weight, strength, heat- and impact-resistance requirements for a critical backstop subassembly. Proto3000 stepped in with metal 3D printing capabilities (Studio System), giving the team rapid, in-house iteration and the design freedom to create lightweight, high-strength geometries that traditional machining or outsourced suppliers could not deliver quickly or affordably.

Proto3000 printed both end pieces in AISI 4140 steel with closed-cell infill and cut-outs, which were fastened to a metal cross-bar to form an arena-ready backstop. The result: parts that withstood repeated combat stresses, a 90–95% part cost reduction (from service quotes of $606–$1,285 down to $56) and a 3-day lead time versus weeks, reduced weight, and proven battlefield performance — helping the BattleBots entry win multiple matches, including a 94-second knockout.

BattleBots