Case study - Carbon-fiber tool handle
Case study
Carbon-fiber prototype tool handles: 10 designs for $200 in material
Commercial products manufacturer · FDM (ABS-CF10)
A leading commercial products manufacturer developed a new hand-held tool. The handle had to support the tool with good balance and user comfort.
The challenge
Traditional prototyping meant a casting with a $12,500 mold, or machining handles from solid aluminum billet. Both were slow and costly. Both also forced design limits such as draft angles and cutter size.
The solution
Engineers used FDM with ABS-CF10. This ABS is filled with 10% chopped carbon fiber by weight and is 50% stiffer than standard ABS. That gave the handles enough rigidity.
The results
- 10 different prototype handles for $200 in material
- 98% cost savings compared with the $12,500 casting mold
- First handle in 12 hours instead of 1–3 weeks: 85–95% time savings
- Fast ergonomic validation without tooling
Application: Ergonomic evaluation
Put designs in users’ hands. Check grip, balance and feel, and test several variants without tooling.
Source: Stratasys Application Guide and Stratasys case material. Photo: Stratasys.
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