Case Study: Stream Lion Design halves turbine testing time with Protolabs' Multi Jet Fusion 3D printing

Stream Lion Design Re-Engineers a Modal Hammer with Multi Jet Fusion

Stream Lion Design, led by engineer Paul Sickles, needed a compact, ergonomic modal hammer to collect vibration data inside cramped combustion turbines. Off‑the‑shelf lab hammers were too large and slow for field use, so Stream Lion Design sought a low‑volume manufacturing solution that could deliver durable, precise parts — engaging Protolabs to produce the final design using Multi Jet Fusion 3D printing.

Protolabs manufactured the production-grade nylon hammer via Multi Jet Fusion, delivering tight tolerances, a durable bead‑blasted/black‑dyed finish, and a perfect fit within the assembly. The Protolabs 3D‑printed part performed in the field, doubling data‑collection speed (halving testing time), enabling on‑demand low‑volume production and rapid design iteration while meeting the project’s precision and durability requirements.

Stream Lion Design

Paul Sickles

Owner & Principal Consultant