Case Study: FATHOM achieves scalable, cost-effective high-volume 3D production with Stratasys Continuous Build 3D Demonstrator

Complexity, Cost, Customization are Key Drivers in 3D Printer Evolution

FATHOM, an Oakland, CA-based advanced manufacturing facility, faced the challenge of moving 3D printing beyond rapid prototyping into higher-volume production and convincing customers to adopt additive for end-use parts. Their customers’ “sweet spot” sat at roughly 200–400 parts — the break-even versus injection molding — and FATHOM needed to push that threshold higher while delivering faster lead times and greater design freedom. To meet this demand they partnered with Stratasys and evaluated the Stratasys Continuous Build 3D Demonstrator, a modular automated FDM system.

Stratasys installed the Continuous Build 3D Demonstrator modules at FATHOM (initially a six-module rack), enabling higher throughput, parallel jobs, automated job management and just-in-time production. The system has allowed FATHOM to target 1,000+ parts per run, shorten lead times, reduce costs and scale capacity; a notable example is the Intel Spider Bots project, where FATHOM produced more than 9,700 printed parts in five weeks for $116,000 versus an estimated $400,000 and months if molded. By deploying Stratasys’ Demonstrator, FATHOM can now offer higher-volume FDM parts, greater flexibility, and inventory-free, on-demand manufacturing.

FATHOM

Rich Stump

Principal