3D Printing & Prototyping at Mar‑Bal: Accelerating Composite Innovation

Mar‑Bal is at the forefront of composite manufacturing, integrating advanced 3D printing into our R&D Center to accelerate product development and reduce time‑to‑market.

Our resin‑based printer builds parts layer by layer with a precision laser that cures the resin within a liquid tank. This technology lets us create exact replicas of components before any tooling or mold is produced, identifying design gaps early and saving both time and cost.

Hands‑on prototypes provide a tangible sense of shape, fit and finish that digital models alone cannot convey. As Insulator Product Engineer Mitch McClung explains, “The ability to hold a real part in our hands is invaluable for spotting issues that aren’t obvious on screen.”

In addition to internal design reviews, the printer supports client demonstrations. McClung recounts a recent project for a major OEM: “We printed several iterations of a one‑piece molded design, giving the customer a realistic feel of the product. The printed part captured all curves and radii perfectly, unlike the multi‑piece samples they had previously tried.”

After printing, each part undergoes a rigorous post‑processing workflow:

• Cleaning wash: Isotopic alcohol removes excess resin.
• UV cure chamber: Heat and UV light fully harden the resin.
• Surface finishing: Tooling removal, sanding, and a final alcohol wipe eliminate imperfections.

These steps ensure that prototypes match the exact specifications needed for downstream manufacturing. By investing in state‑of‑the‑art equipment, skilled talent, and continuous education, Mar‑Bal remains the single source of truth for composite solutions, driving innovation for our customers and expanding our portfolio of proprietary products.