High-Precision Prototyping and Metallized Finishes: How Dreamplas Reduced Lead Times with DF2

The Challenge: Lead Times and Flexibility

Before integrating 3D printing into their workflow, Dreamplas relied on subcontracting external services to produce prototypes. These physical 3D models were essential for presenting concepts to clients, testing assembly fittings, and validating mechanical functionality and aesthetics. However, this process faced limitations, particularly in lead time and flexibility.

The main challenge was finding subcontracting partners capable of delivering prototypes within extremely tight deadlines, often requiring parts in less than 24 hours, which was rarely achievable through external suppliers.

The Solution: Internalizing Prototyping with 3D Printing

Dreamplas adopted 3D printing to internalize its prototyping process, enabling faster production of prototypes, assembly fitting tests, mechanical functionality checks, and visual evaluations of models, including post-processed and metalized parts, to assess proportions, ergonomics, and aesthetics.

To support this workflow, the company selected the Raise3D DF2, a high-precision DLP (Digital Light Processing) 3D printer recognized for its outstanding surface quality, fine print resolution, and ability to produce functional, visually refined prototypes with or without additional post-processing.

Combined with Raise3D Standard White Resin, chosen for its mechanical strength, smooth surface finish, and versatility, Dreamplas achieved consistently high-detail prototypes, significantly improving over previous materials and meeting the demands of both client demonstrations and functional testing.

Application Highlight: Precision Prototyping for the Cosmetics Industry

One of Dreamplas’ projects involved the development of a packaging component for the cosmetics sector. The main challenge was producing prototypes with tiny functional features, often below 1 mm, and tolerances within hundredths of a millimetre.

 “The main challenge in the prototyping and product development phase was related to dimensions,” explains Carlos Carreira. “We’re talking about measurements below 1 millimetre, and to obtain a good prototype, the printing technology needs to deliver precision down to hundredths, not tenths. A variation of just 0.05 mm is enough for parts not to fit.”

FFF (Fused Filament Fabrication) printing proved unsuitable, due to its limited dimensional accuracy and porosity.

“With filament, it’s very difficult to get realistic feedback on how the final plastic part will behave. You simply can’t work at those reduced dimensions,” adds Carlos.

Using the DF2, Dreamplas produced a series of high-precision resin prototypes, iterating between print runs and model adjustments to achieve perfect assembly fits.

“We had to adjust certain dimensions in the 3D model, print, and test the fits. That’s where this fine-tuning of hundredths, 5 hundredths, sometimes even less, comes in. This was particularly important for features like the thread, which may seem like a simple mechanical detail, but it’s actually the most critical part of the assembly. Everything depends on the functionality of this thread: testing angles, testing contact surfaces, evaluating the effort the cap exerts on the jar. We also tested for water tightness, something that’s impossible to validate with porous printing process like filament. The resin made these functional validations feasible.”

– Carlos Carreira, Engineering and Product Development at Dreamplas

He also noted that material properties were another important factor:

“Then comes the material quality in terms of mechanical characteristics like tensile limits and stiffness, the printed prototypes are in many cases superior to the final injected plastic parts. It already gives a very good idea of the product’s functionality, especially considering that we’re working at extremely small dimensions.”

Fast Iteration and Process Control

Previously, outsourced prototypes could take a week or longer. Now, Dreamplas can produce and validate parts in less than 24 hours.

“That’s the biggest difference,” Carlos states. “We went from waiting a week or more to less than a day. We can print, test, adjust, and reprint immediately if needed.”

– Carlos Carreira, Engineering and Product Development at Dreamplas

The DF2 also allows Dreamplas to control print orientations depending on whether a mechanical or aesthetic area is being evaluated, ensuring precision where needed and optimizing critical zones.

Surface Finishing and Post-processing

An added benefit was the high surface quality achieved with the DF2. Even with simple post-processing, primarily sanding and polishing, parts achieved smooth, high-quality finishes, suitable for additional processes like metallization.

“We went an extra mile here. It’s not something you normally do with prototypes, but it allowed us to clear some client doubts. With metallization, we could present a part that looked, and performed like the final product.”

Software Experience

Dreamplas uses ideaMaker® to manage print preparation and settings. The software impressed the team with its:

• Intuitive interface
• Automatic part positioning and support generation
• Analysis tools for identifying and addressing critical support areas

These features streamlined the preparation of print files, making the prototyping process faster, more efficient, and repeatable.

Results

Today, Dreamplas produces 10 to 15 prototypes per month using the DF2, adjusting output based on project demands. The combination of faster turnaround times, precise dimensional accuracy, and superior surface finishes has transformed their product development workflow.

Key benefits achieved:

• Fast, in-house production of high-quality prototypes
• Precise control over part tolerances and finish
• Improved visual and tactile quality of prototypes
• Enhanced mechanical functionality of printed parts
• The ability to validate design concepts and product functions more effectively, and within tight deadlines

The feedback from Dreamplas’ clients has been very positive, particularly regarding the quality, appearance, and functionality of the 3D printed prototypes.

Future Plans

Based on the success with the DF2, Dreamplas plans to expand its 3D printing capabilities by investing in additional technologies and further integrating additive manufacturing into its service offering.

“If you have creativity and a willingness to experiment, you can achieve excellent results with this technology,” Carlos concludes. “It’s about understanding what the part needs, how the printing process works, and then pushing the technology to deliver what you’re aiming for.”