01
The build needs a tolerance the printer cannot hold
A mating bore and a shaft both come off the machine out of spec. Sanding and shimming follow. We machine those features after printing so the fit works on first assembly.
Custom 3D Printing
3D Printing Service
We build functional prototypes and low-volume parts in plastic and metal. FDM, SLS, SLA and DMLS, then CNC finishing when the fit or finish needs machining tolerances.
30+ materials10+ surface finishesTolerances down to ±0.005 mmNo minimum order quantity
15 yearsManufacturing experience
127CNC machines in house
±0.005 mmMachining tolerance
3–5 daysTypical part shipping
Where printed parts go wrong
Four problems we see on almost every printed prototype
02
Layer lines show on a customer-facing surface
Visible stepping on a housing makes a working prototype look unfinished. Bead blasting, tumbling or a light skim cut removes the texture without changing the geometry.
03
The resin or filament fails in service
A bracket cracks under load or a part softens near a heat source. Material choice matters more than print resolution here; we match resin, nylon or metal to the working conditions.
04
Printing is quoted as a standalone process
You get printed parts with no path to finishing or machining. We run print, CNC and surface finishing in the same plant, so the part arrives ready to use.
How we run the job
One shop for printing, machining and finishing
Print the shape, then bring the critical features to tolerance.
Process selection
Pick the process by what the part has to do
Resolution is not the first question. Ask what the part has to survive: a fit check, a drop test, a heat cycle or a full production run. FDM covers large brackets and enclosures in ABS or PC at low cost per part. SLS gives nylon parts with no support marks and good strength in any direction. SLA holds fine detail for small features and smooth surfaces. DMLS builds metal parts in titanium and Inconel when the geometry cannot be milled.
We quote one process, not four, when the job does not need them. If a part has three critical bores, printing the body and machining those bores is usually cheaper than printing the whole part in metal.
- 1FDMLarge enclosures, brackets, jigs. Layer lines visible unless finished.
- 2SLSNylon parts with isotropic strength. Good for snap fits and living hinges.
- 3SLA and DMLSFine detail in resin, dense metal where milling cannot reach.
Post-print machining
Machining after printing is what makes parts fit
A printed part is close, not accurate. Faces that bolt to something else, bores that take a bearing and threads that carry load all need a cut. Our 127 CNC machines take printed blanks and bring those features to ±0.005 mm. The printed body keeps the shape that would be expensive to mill; the machined features keep the fit.
This matters most in the transition from prototype to production. The same geometry that was printed for a fit check can be machined from 6061 or 17-4PH for the pilot run, so the drawing does not change.
- 1Datum facesFace and square the mounting surfaces before anything else.
- 2Bores and threadsReam bearing seats, tap threads, hold concentricity on mating pairs.
- 3Surface finishRa 0.8–1.6 μm on sealing faces. Printed texture removed where it matters.
Process comparison
Which process fits the part
Use this to narrow the choice before you send files.
| Process | Typical use | Hold on fine detail | Watch out for |
|---|---|---|---|
| FDM | Enclosures, brackets, jigs | Moderate | Visible layer lines, weak in Z |
| SLS | Snap fits, duct covers, ducts | Good | Grainy surface, needs blasting |
| SLA | Small features, smooth housings | High | Brittle under impact, UV aging |
| DMLS | Metal ducts, manifolds, brackets | High | Higher cost, support removal |
| Print + CNC | Parts with critical fits | High on machined faces | Two setups, plan datum early |
What we run
Services behind a finished printed part
01
FDM printing
ABS, PC, PETG and filled filament for large parts and shop fixtures. Good starting point when cost per part drives the decision.
02
SLS printing
Nylon 12 and glass-filled nylon. No support marks, strength in all directions, works for functional testing.
03
SLA printing
Fine feature resin for small parts and smooth surfaces. Detail where an FDM nozzle cannot reach.
04
DMLS metal printing
Titanium, Inconel and stainless builds for dense metal parts with internal channels.
05
CNC finishing
5-axis and mill-turn work on printed blanks. Datum faces, bores, threads and seal faces.
06
Surface finishing
Bead blasting, tumbling, anodizing, plating and laser marking to match the final look.
Scope and limits
What the quote covers
| Item | Included | Notes |
|---|---|---|
| Build size | Up to 4,000 mm on CNC finishing | Print envelope depends on process |
| Materials | 30+ plastics and metals | ABS, PC, PA, PEEK, Ti-6Al-4V, Inconel |
| Tolerance | ±0.005 mm on machined features | As-printed tolerance is wider |
| Surface finish | Ra 0.8–1.6 μm on cut faces | As-printed texture varies by process |
| Order size | One part to 10,000+ | No minimum order quantity |
| Inspection | 100% before shipment | Reports on request |
Why GreatLight
Reasons engineers send repeat work
15Y
Printing and machining since 2011
Started as a CNC shop. That is why we treat printed parts as blanks that still need a cut, not as finished goods.
127
CNC machines on site
16 simultaneous 5-axis centers, 12 four-axis mills and 16 mill-turn centers for post-print work.
12 h
Quote and DFM analysis
Send a model and a drawing. You get a price and a written note on wall thickness, draft and datum choices.
4
Quality systems in place
ISO 9001, IATF 16949, ISO 13485 and ISO 27001. Your files stay confidential; NDA on request.
99.99%
Qualification rate
Raw material check, in-process monitoring and final inspection before anything ships.
<2%
Late-delivery probability
Historical figure across production orders. Production can start within 24 hours of a released order.
7,600 m²Manufacturing space
3Wholly-owned plants
150Technicians
30+Materials available
Industry fit
What these industries require, and what we deliver
Medical device housings
Requirement: clean surfaces, traceable resin, tight lid fit.
- SLA resin
- ISO 13485 process
- ±0.005 mm on mating faces
Automotive brackets
Requirement: survive vibration and heat near the engine bay.
- Glass-filled nylon
- SLS build
- Machined mounting bores
Electronics enclosures
Requirement: flat lid, controlled wall thickness, no layer lines on the face.
- FDM ABS
- Bead blast finish
- Snap fits tested
Industrial ducts and manifolds
Requirement: internal channels that milling cannot reach, dense walls.
- DMLS Ti-6Al-4V
- Machined flanges
- Pressure-tested
FAQs
Questions we get before a first order
When should I print a part instead of machining it?
Print when the geometry is complex, the quantity is low, or the design is still moving. Internal channels, lattice sections and organic shapes are cheap to print and expensive to mill.
Machine when the part has tight tolerances, threads under load, or a surface finish spec. For a part that needs both, we print the body and machine the critical features.
What tolerance can you actually hold on a printed part?
As-printed dimensions vary by process and part size. FDM and SLS parts hold roughly ±0.3 mm on small features, and less on long spans.
After CNC finishing, machined faces and bores hold ±0.005 mm. If a dimension matters for assembly, put it on a machined feature.
How do I choose between SLS and SLA?
SLS for parts that take load or need strength in every direction. No supports, so no marks on hidden faces.
SLA for small features and smooth surfaces, such as display models or fine-texture housings. It is more brittle, so avoid it for impact parts.
Can printed parts be anodized or plated?
Plastic prints take bead blasting, tumbling, painting and laser marking. Anodizing and plating apply to metal parts, including DMLS builds.
Laser marking needs a minimum character height of 1.5 mm to stay legible after finishing.
What file formats do you need?
STEP or STL for the model, plus a 2D drawing for anything with a tolerance, thread or finish callout.
Mark datum faces on the drawing. That single note often removes an extra setup.
Is there a minimum order quantity?
No minimum. One prototype or 10,000+ parts, quoted the same way.
For runs above a few hundred, we usually compare printing against machining or casting and tell you which one is cheaper.
How fast can you turn a quote and a part?
Quote and DFM analysis within 12 hours. Production can start within 24 hours of a released order.
Typical parts ship in 3–5 days. Complex metal builds or finishing steps take longer, and we say so in the quote.
How do you handle confidentiality?
Uploads stay confidential and are handled under ISO 27001 controls. We can sign an NDA before you send files.
Files are used for your job only. No public case studies or galleries without written approval.
Send a model, get a quote and a DFM note
Upload your STEP file and drawing. We reply within 12 hours with pricing, a process recommendation and any changes worth making before the build.
12-hour quote100% inspectionNo minimum order quantityNDA on request
