Leverage 3D Printing to Accelerate Lifecycle Testing

In the competitive world of component validation, rapid iteration and reliable test setups are critical. Lýseon Additive Manufacturing partnered with a customer to design and produce a custom 3D-printed holding fixture. This fixture enabled efficient lifecycle testing on a pin and pin receiver assembly. By applying advanced additive manufacturing capabilities, Lyseon reduced lead time, optimized cost, and delivered a precise, durable solution that met the customer’s technical requirements.

Our customer needed to conduct lifecycle testing on a pin and pin receiver to validate performance under repetitive use. Their challenge was twofold:

1. Custom Geometry Requirement: A specialized holding fixture was required to secure the parts in a repeatable, reliable manner during testing.
2. Time Constraints: Conventional machining of such a fixture would have resulted in long lead times and higher costs, delaying the customer’s testing schedule.

Without a properly designed fixture, the customer risked inconsistent test results and prolonged project timelines.

We engaged with the customer through a collaborative engineering process that focused on three key steps:

1. Requirements Definition: Working closely with the customer, Lyseon AM gathered precise details on fixture geometry, tolerances, and performance requirements.
2. Design and Simulation: Using CAD and additive design principles, Lyseon AM developed a fixture design optimized for strength, accuracy, and ease of use. Structural simulations ensured the fixture could withstand repetitive load cycles.
3. 3D Printing and Post-Processing: The fixture was produced using industrial-grade 3D printing technology with a high-strength polymer material, ensuring both durability and dimensional stability. Post-processing steps included surface finishing and dimensional inspection.

The partnership delivered measurable benefits for the customer:

• Rapid Delivery: The fixture was designed, printed, and delivered in a fraction of the time compared to conventional machining.
• Cost Efficiency: Additive manufacturing minimized material waste and eliminated the need for complex tooling.
• Precision and Reliability: The 3D-printed fixture securely held the pin and receiver assembly, ensuring repeatable test results.
• Flexibility: The digital design allowed for quick adjustments and iterations if modifications were required during the testing process.

With the 3D-printed holding fixture in place, the customer successfully executed lifecycle testing on the pin and pin receiver. The solution allowed the customer to:

• Accelerate product validation timelines.
• Generate consistent, reliable data from testing.
• Reduce overall testing costs.
• Improve their ability to bring products to market faster.

This project highlights how Lýseon’s expertise in fixture design and 3D printing provides customers with practical, cost-effective solutions to testing and validation challenges. By leveraging additive manufacturing, customers gain access to rapid prototyping, reduced lead times, and fixtures that are tailored to their exact requirements.

Lýseon continues to support customers across industries by delivering innovative, high-performance solutions that accelerate product development and testing.

For more info about leveraging 3D printing to accelerate lifecycle testing, from the experts at Lyseon Additive Manufacturing, please contact us here or call us directly at 248.514.1829.