Case Study: 3D-Printed Display Rack Solution for an Optical Retailer

Introduction

At Print That, we often receive requests from local businesses looking to replace or upgrade unique components that aren’t readily available on the market. Recently, we were approached by an optical retailer in need of a replacement part for a display rack. The part needed to securely hold glasses by the nose bridge, allowing them to stay positioned yet fully visible to customers. With the original part unavailable from the manufacturer, the store sought a custom solution that would replicate the original functionality and aesthetic. This project allowed us to apply our expertise in 3D modeling and prototyping, as well as our commitment to precision and customer satisfaction.

Project Objectives

The client outlined several objectives for the part:

• Functionality: The part needed to hold glasses by the nose bridge securely without obstructing the view of the glasses.

• Aesthetics: It was essential that the part was either transparent or minimally intrusive to maintain the store’s clean and polished display.

• Durability: The new part needed to withstand regular handling and adjustments without cracking or deforming.

Given these requirements, we decided to prototype the part in black PLA and then finalize it in clear PETG to meet both functional and visual criteria.

Process Overview

1. Design and Modeling: The design process began with creating a digital model that would replicate the existing part, matching its dimensions and functionality. The modeling took around two hours and involved designing two distinct versions:

   • Replica Version: This design closely followed the original part’s structure, ensuring a direct fit with the existing display rack.

   • Strengthened Version: This alternative included additional ridges to reinforce the structure, particularly around areas of the part that had broken on the original. The added ridges aimed to prevent stress-related breakage from frequent handling.

2. Prototyping: With the digital models ready, we proceeded to print both versions using black PLA filament. PLA was selected for the prototype stage due to its ease of handling, strength, and suitability for testing purposes. The prototypes allowed us to assess both designs in real-world use and determine which would best meet the client’s durability requirements.

3. Testing and Evaluation: During testing, both versions performed well in terms of holding the glasses securely while maintaining the desired aesthetics of the display. The replica version provided a close visual match to the original part, while the strengthened version displayed enhanced durability due to the additional ridges. Testing confirmed that both designs met the functional requirements, and we felt confident presenting both options to the client for feedback.

4. Material Selection: To align with the client’s request for a clear, minimally visible component, we recommended finalizing the design in clear PETG. PETG offers excellent transparency, flexibility, and impact resistance, making it an ideal choice for displays where both visibility and durability are critical. Unlike PLA, PETG has a slight flexibility, which helps it absorb impacts better and reduce the likelihood of breakage under stress. The clear material would integrate seamlessly into the display, enhancing both aesthetics and longevity.

Customer Feedback and Pending Approval

Currently, both prototypes are under review by the client, and we are awaiting their feedback. The side-by-side comparison allows them to see how each design performs in a real retail environment, where frequent adjustments and durability are essential. We are optimistic about the client’s response, as both prototypes align well with their goals, and we’re prepared to move forward with clear PETG production based on their final selection.

Results and Reflections

Even before final approval, this project has proven successful in several ways:

• Achieving Design Precision: By creating two distinct versions—one replica and one strengthened—we were able to balance both functional and aesthetic demands, providing the client with options based on their specific needs.

• Flexibility in Material Selection: Our approach of prototyping in black PLA before finalizing in PETG demonstrates our commitment to finding materials that both enhance functionality and suit our clients’ preferences.

• Meeting Unique Business Needs: This case underscores our ability to work closely with businesses in various industries to address unique challenges that mass-produced parts may not solve.

Conclusion

This project exemplifies Print That’s dedication to creating custom solutions for local businesses. Through careful design, prototyping, and material selection, we were able to deliver a product that not only meets the practical needs of the client but also aligns with their aesthetic requirements. Projects like these highlight the versatility of 3D printing in creating tailored, precise components for applications that traditional manufacturing may not readily accommodate.

For optical retailers and other businesses that depend on display components to showcase their products, Print That provides reliable, high-quality solutions designed with both performance and visual appeal in mind. We’re thrilled to have taken on this project and look forward to helping more businesses with their specialized 3D printing needs.