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3D Printing Service & Custom 3D Modeling Solutions

Cusack Electronics is a professional 3d printing service and 3d modeling services provider supporting OEMs and product teams that need functional parts, accurate prototypes, and production-ready components without managing multiple vendors. Our in-house SolidWorks CAD team and FDM, SLA, and SLS capabilities take your concept from digital model to finished physical part under one roof, delivering reliable 3d model design services and 3d printer service support at every stage of your build.

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Additive Manufacturing Expertise

From Digital Model to Finished Part

Our 3D printer service and 3D model design services support engineers, product developers, and OEMs who need rapid turnaround on functional parts, concept models, enclosures, connectors, brackets, and custom components. We combine in-house SolidWorks parametric modeling and surface modeling with FDM, SLA, and SLS printing technologies to produce accurate, repeatable parts built to your dimensional and material requirements.

  • Full 3D modeling services from concept sketch through production-ready STEP and STL files, using SolidWorks parametric and solid modeling with DfAM principles applied throughout.
  • FDM, SLA, and SLS printing technologies cover a broad material range, including PLA, ABS, ASA, PETG, nylon (PA12), TPU, polycarbonate, ULTEM 9085, and photopolymer resins.
  • Dimensional accuracy and layer resolution are controlled to project requirements, with wall thickness analysis, shrinkage compensation, and warping mitigation built into every build setup
  • Post-processing capabilities include support removal, sanding, vapor smoothing, painting, UV coating, and epoxy sealing for surface finish and functional readiness.
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Our Services

Complete 3D Modeling & Printing Capabilities

Every part of your product needs to be modeled to specification and printed to functional tolerance. From parametric CAD modeling and DfAM review through FDM, SLA, and SLS production and post-processing, our 3D printing service covers the complete additive workflow.

SolidWorks 3D Modeling

Parametric modeling, surface modeling, and solid modeling in SolidWorks for enclosures, brackets, connectors, housings, and custom components. STEP, STL, and OBJ file outputs are ready for print or downstream machining and tooling.

Altium Designer

KiCad

BLE / WiFi

Eagle CAD

IoT Ready

Multi-Layer

FDM Printing

Fused deposition modeling for functional prototypes, jigs and fixtures, tooling inserts, and end-use parts in PLA, ABS, ASA, PETG, nylon, polycarbonate, TPU, and ULTEM 9085. Large build volumes with controllable infill density and wall thickness.

Altium Designer

KiCad

BLE / WiFi

Eagle CAD

IoT Ready

Multi-Layer

SLA Resin Printing

Stereolithography for high-detail parts requiring fine layer resolution and smooth surface finish. Photopolymer and engineering resin materials produce accurate concept models, master patterns, and functional components with tight dimensional accuracy.

C / C++

RTOS

BLE / WiFi

Arduino

IoT Ready

SLS Nylon Printing

Selective laser sintering for durable, production-grade parts in nylon (PA12) and carbon fiber-filled filament without support structures. Ideal for complex geometries, interlocking assemblies, and batch production of functional components.

C / C++

RTOS

BLE / WiFi

Arduino

IoT Ready

Design for Additive Manufacturing (DfAM)

DfAM review is built into every modeling engagement, catching wall thickness issues, overhangs, unsupported features, and infill requirements before the file goes to print, reducing failed builds and protecting turnaround time.

C / C++

RTOS

BLE / WiFi

Arduino

IoT Ready

Rapid Prototyping

Quick-turn functional prototypes and concept models for iterative design validation. From the first STEP file to the finished prototype, our workflow compresses the feedback loop between design and physical part.

C / C++

RTOS

BLE / WiFi

Arduino

IoT Ready

Low-Volume & Pilot Production

Batch production and pilot runs of 1 to 500+ parts using FDM, SLA, and SLS processes, supporting bridge production between prototype and injection molding tooling without minimum order commitments.

C / C++

RTOS

BLE / WiFi

Arduino

IoT Ready

Reverse Engineering & 3D Scanning

Reverse engineering for legacy components, worn tooling, or parts without original CAD data. 3D scanning captures physical geometry and delivers accurate STEP files ready for reproduction or design modification.

C / C++

RTOS

BLE / WiFi

Arduino

IoT Ready

Post-Processing & Finishing

Support removal, sanding, bead blasting, vapor smoothing, painting, dyeing, UV coating, and epoxy sealing are applied after printing to meet surface finish, dimensional, and cosmetic requirements for end-use and customer-facing parts.

C / C++

RTOS

BLE / WiFi

Arduino

IoT Ready

Our Process

From CAD File to Finished Part in Five Steps

A structured additive manufacturing workflow designed to deliver accurate, functional parts on schedule with full visibility from model review through finished delivery.

01

Submit Your Design or Brief

Upload your STEP, STL, or OBJ file, or share a sketch, reference part, or product brief. We review geometry, wall thickness, material requirements, and quantity and respond within 24 hours.

Consultation

Feasibility Study

NDA Available

02

3D Modeling & DfAM Review

For parts requiring original CAD, our SolidWorks team builds parametric models with DfAM principles applied throughout. For supplied files, we run wall thickness analysis, overhang checks, and mesh repair before print preparation.

Schematic Capture

BOM Generation

Circuit Simulation

03

Material & Process Selection

We recommend the right printing technology and material based on your mechanical requirements, surface finish targets, dimensional accuracy needs, and production volume. FDM, SLA, or SLS matched to the application.

Gerber Files

3D CAD

DFM Review

04

Printing & Quality Control

Parts are built on our in-house printers with layer resolution, infill density, and build orientation set to your specifications. Dimensional accuracy is verified against the original CAD file before post-processing begins.

Embedded C/C++

Unit Testing

Source Code Delivery

05

Post-Processing & Delivery

Support removal, surface finishing, and any secondary operations are completed before final inspection. Parts ship with documentation and are available to move directly into our powder coating, UV printing, or assembly workflows.

Functional Testing

Debug & Iteration

Client Approval

Technical Specifications

3D Printing Specs & Tolerances

Our in-house printing equipment and modeling software handle a wide range of part sizes, materials, and precision requirements across FDM, SLA, and SLS technologies.

PCB & Electronics Design Specs
Machining EnvelopeUp to 40" × 20" × 20" (VMC), 60" × 30" × 30" (HMC)
Minimum Tolerance±0.001" (0.0254mm) standard, ±0.0005" (0.0127mm) on request
±0.001" (0.0254mm) standard, ±0.0005" (0.0127mm) on request
Surface FinishRa 32 μin standard, Ra 16 μin or better achievable
Hole Diameter Range0.040" to 4.000" with drill bits, reamers, and boring bars
Thread Sizes#2-56 through 1"-8 UNC/UNF, metric M2 through M24
Materials Supported Aluminum, steel, stainless, titanium, brass, copper, plastics
Axis Configuration 3-axis, 4-axis, 5-axis milling
Batch Sizes1 piece prototypes to 10,000+ production runs
Inspection EquipmentCMM, optical comparator, micrometers, calipers, profilometer
Standards ComplianceISO 2768, ASME Y14.5, ISO 1302

Software & Equipment

Tools We Use

Modeling Software and Printing Equipment Powering Every Build Professional-grade CAD software and additive manufacturing equipment ensuring dimensional accuracy, material consistency, and reliable turnaround across all 3D modeling services and 3D printer service operations.

SolidWorks

Parametric, surface, and solid modeling for all original CAD work, DfAM review, and STEP and STL file generation

FDM Printers

Industrial FDM systems for thermoplastic materials, including ABS, ASA, PETG, nylon, polycarbonate, TPU, and ULTEM 9085

SLA Resin Printers

High-resolution vat photopolymerization systems for photopolymer and engineering resin parts with fine layer resolution

SLS Systems

Selective laser sintering equipment for nylon (PA12) and carbon fiber-filled filament parts without support structures

3D Scanning

structured light and contact scanning for reverse engineering legacy parts and capturing physical geometry for CAD reconstruction

Slicing & Build Prep Software

Professional slicing tools for build orientation, support generation, infill density, and layer height optimization before every print

Post-Processing Equipment

Support removal stations, sanding and bead blasting equipment, vapor smoothing systems, and UV coating application for surface finishing

Quality Inspection Tools

Digital calipers, micrometers, and coordinate measurement for dimensional verification against original CAD geometry before shipment

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Recent Work

Featured Projects

Professional Guitar Effects Pedal

Full design and production of a boutique analog delay pedal — from schematic, PCB layout, and firmware to CNC aluminum enclosure, UV printing, and final assembly.
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Industrial IoT Sensor Gateway

Multi-sensor BLE gateway with Cortex-M4 processor, custom firmware, 10-layer PCB, and ruggedized enclosure — designed for factory floor deployment in harsh environments.
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Portable Patient Monitoring Device

Low-power embedded system with BLE connectivity, high-accuracy analog front end, 6-layer PCB, injection-molded enclosure design, and IPC-A-610 Class 3 assembly.
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Recent Work

Ready to Turn Your Model into a Physical Part?

Upload your STEP or STL file, or share your product brief, and our team will respond within 24 hours with material recommendations, process selection, and a detailed quote.
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Common Questions

Frequently Asked Questions

What 3D printing technologies do you offer?

We offer FDM (fused deposition modeling), SLA (stereolithography), and SLS (selective laser sintering) in-house. FDM covers a broad range of thermoplastic materials, SLA delivers high-detail resin parts, and SLS produces durable nylon components without support structures.

Both options are available. Our SolidWorks team provides full 3D model design services from concept through production-ready STEP and STL files. If you already have a CAD file, we run a DfAM review and prepare it for print.

We accept STEP, STL, OBJ, IGES, and native SolidWorks files. If your design exists only as a sketch, reference part, or physical sample, our reverse engineering and 3D scanning services can capture the geometry and build the CAD model.

Our material range includes PLA, ABS, ASA, PETG, nylon (PA12), TPU, TPE, polycarbonate, ULTEM 9085, photopolymer resins, and carbon fiber-filled filament. Material selection is matched to your mechanical, thermal, chemical resistance, and surface finish requirements.

General dimensional accuracy is ±0.2mm or ±0.1%, whichever is greater, depending on geometry and material. SLA delivers the tightest layer resolution at 0.050mm minimum. Critical dimensions and tolerance callouts can be addressed through process selection and post-machining.
Can you handle low-volume production runs, not just prototypes?

Yes. Our SLS and FDM capabilities support batch production and pilot runs from 1 to 500+ parts. We also support bridge production between prototype validation and injection molding tooling without minimum order requirements.

Post-processing includes support removal, sanding, bead blasting, vapor smoothing, painting, dyeing, UV coating, and epoxy sealing. For finishing integration, printed parts can move directly into our powder coating and UV printing workflows.

 Rapid prototyping typically ships in 2 to 5 business days depending on geometry complexity and material. Low-volume production batches and parts requiring extensive post-processing are quoted with lead times based on quantity and finishing requirements.

Yes. Parts produced through our 3D printer service are built to your dimensional specifications and can be designed with assembly features, threaded inserts, press-fit interfaces, and mating geometries for direct integration into enclosures, PCBs, harnesses, and product builds.

Yes. Our additive manufacturing capability integrates with CNC machining, wire harness assembly, powder coating, UV printing, PCB assembly, and full product assembly under one roof, letting you consolidate vendors and compress lead times on the finished product.

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