Dunlop Systems Accelerates Tooling Production with 3D Printing – Insights from Mark Statham

Jigs, fixtures and other tooling aids form the backbone of any production floor. Yet it’s not uncommon for these tools to take weeks to produce, creating bottlenecks that stall the entire workflow.

To eliminate these delays, Dunlop Systems and Components, a UK automotive‑manufacturing specialist, embraced 3D printing in late 2018. Within nine months, the company was printing tooling parts and prototypes in just a few days, slashing lead times from weeks to hours.

In this interview, Production and Engineering Manager Mark Statham discusses how the company adopted additive manufacturing and the tangible benefits it delivers across its operations.

Could you tell me a bit about Dunlop Systems and Components?

Dunlop Systems traces its roots back to the original Dunlop company of the 1960s, initially producing suspension systems for vehicles such as the Mini Metro. Over the decades, the company expanded into air suspension solutions for major automotive brands – Land Rover, GM, Isuzu, Renault, and specialty trucks – and later ventured into niche markets including ambulance and wheelchair‑access vehicles.

In 2014, Dunlop moved into a purpose‑built facility, allowing the launch of the Dunlop Systems brand and opening doors to new market segments.

What type of customers and industries does Dunlop serve?

Primarily, Dunlop serves the automotive sector, supplying high‑end suspensions for Land Rovers, Discoveries, and other premium brands, as well as parts for Renault and Dennis Specialist Vehicles.

The company also supports the rail industry – Bombardier is a key customer – producing valves and other components. Additionally, Dunlop’s suspension units are used for industrial machinery lifting and vibration suppression, and even in fairground ride bellows, demonstrating the breadth of its market reach.

What prompted the company’s decision to consider additive manufacturing?

Customer demand for shorter lead times, from concept to start‑of‑production, highlighted the need for faster design‑to‑manufacture cycles. With tight budgets and a desire to fund new development projects, Mark Statham identified 3D printing as a cost‑effective solution that could reduce tooling expenses and accelerate time‑to‑market.

Was it difficult to get buy‑in for additive manufacturing?

Design engineers had already experimented with 3D printing a few years earlier, but early trials revealed that existing materials couldn’t meet the endurance requirements of Dunlop’s high‑mileage suspensions. A Markforged seminar in 2019 showcased advanced composite materials and real‑world use cases, convincing the director to support a pilot program.

Mark built a cost‑analysis spreadsheet, identifying roughly 100 tooling parts that could benefit from on‑site printing. After factoring in purchase and operating costs, the payback period was projected at two years – a figure that accelerated decision‑making and led to a printer delivery within three weeks.

What was the early deployment process like?

Within an hour of the printer’s arrival, the team began with the most critical tooling items. They prioritized simple, high‑impact replacements – such as white nylon jigs – and printed them in Markforged’s Black Onyx, which offered superior strength and reduced wear.

Traditionally, replacing a tool could take 2–3 weeks from quotation to delivery. The new workflow cut this to a matter of hours, dramatically improving shop‑floor productivity and demonstrating tangible ROI to management.

Has your use of 3D printing evolved over the nine months?

Yes. The team now prints complex, high‑performance parts, including interlocking assemblies and custom clamps. They’ve developed a 3‑step bonding technique that ensures structural integrity while keeping weight low.

For niche customers – such as wheelchair‑access vehicle manufacturers – Dunlop can now provide bespoke tooling that is both cost‑effective and tailored to tight budgets. The printer also produces prototype components for design and quality teams, reducing the need for expensive CNC machining.

Was internal expertise a challenge?

The department, comprising five members, quickly mastered the printer’s capabilities and expanded usage across other departments. Quality control now uses 3‑D printed gauges, and the design team relies on rapid prototypes for concept validation.

While 3‑D printing remains ideal for development, large‑scale production of millions of units still requires traditional moulding. Dunlop is exploring a hybrid approach, using 3‑D printed tooling to expedite mould design and then transitioning to injection moulding for volume runs.

What’s Dunlop’s vision for 3‑D printing going forward?

Short‑term: Replace the current tooling line over the next 12–18 months using 3‑D printed components that incorporate carbon‑fibre reinforcement for added strength.

Long‑term: Evaluate 3‑D printing for legacy parts, such as the 1960s levelling valves used by Virgin Trains and Bombardier, which could be refurbished or re‑manufactured to reduce scrap and improve reliability.

Additionally, Dunlop is researching recycling options for worn moulds, leveraging additive manufacturing to create replacement mould sections on demand.

What does the next year hold for Dunlop?

2026 will see the launch of a new electric‑vehicle platform and expanded ECAS systems across OEMs, all certified under IATF 16949. The aftermarket will remain a core focus, alongside the development of anti‑vibration components for industrial applications.

To meet growing demand, Dunlop plans to acquire a second, larger 3‑D printer, doubling production capacity and enabling faster turnaround for both tooling and prototypes.

To learn more about Dunlop Systems, visit: https://www.dunlopsystems.com/