Case Study: Orange County Choppers achieves 67% cost savings and 80% faster lead times with Stratasys 3D Printing

3D Printing Breathes Life into Orange County Chopper's Dragon Motorcycle

Orange County Choppers (OCC) builds custom and production motorcycles and was struggling with the time, cost and weight of one-off, intricately detailed parts when produced by traditional CNC machining or carved high-density foam. To preserve ambitious design detail—like a fully realized Chinese dragon head—while reducing lead times and labor, OCC turned to Stratasys and its Fortus 400mc 3D Production System (additive manufacturing).

Using the Stratasys Fortus 400mc, OCC printed exact replicas straight from STL files, including fine surface detail and internal voids/sparse infill to cut weight. The change cut part cost from $2,400 to $800 (a $1,600, or 67% savings) and reduced lead time from about 15 days to 3 days (saving 12 days, an 80% reduction), enabling faster, lighter, lower‑cost production without sacrificing design freedom.

Orange County Choppers

Jason Pohl

Graphic Artist and Designer