Glassboard: Leveraging 3D Printing for Rapid, Reliable Product Development

Glassboard’s mission is clear: partner with the world’s boldest companies to create products that people love. Rather than stopping at CAD files or slide decks, the team guides clients through manufacturing, pricing negotiations, and supply‑chain setup, delivering a turnkey solution from concept to market launch.

Operating across industries—cycling, healthcare, consumer electronics, and more—Glassboard relies on Formlabs 3D printers to push the boundaries of design. VP of Operations Grant Chapman explains, “We’re a jack‑of‑all‑trades developer, but we’ve built enough in‑house expertise to tackle any challenge. The Form 2 and Form 3BL, coupled with Formlabs’ expansive material range, let us serve every vertical with the same level of precision and speed.”

Material Diversity: A Resin for Every Need

Glassboard’s success hinges on access to a comprehensive resin library. BioMed Clear Resin, for example, produces transparent molds that reveal air bubbles or defects during inspection, while Tough 2000 Resin allows parts to endure rigorous impact testing.

From injection molding to thermo‑forming and silicone casting, each project demands a distinct workflow. As Chapman notes, “The larger the material library, the smoother my workflow becomes.”

A recent partnership with Sunny, a menstrual‑cup manufacturer, showcased this flexibility. The product’s flexible, body‑contact design required extensive prototyping. Using Elastic 50A and Flexible 80A resins, Glassboard simulated the cup’s elasticity, while Tough 2000 Resin ensured impact resilience for a safety‑critical component.

Three resins stand out in the Glassboard toolkit:

1. Tough 2000 Resin – Ideal for functional parts such as snap‑fits and living hinges; its performance mirrors that of production plastics.
2. Draft Resin – Combines speed and accuracy, enabling rapid iteration without compromising detail.
3. Rigid 10K Resin – Delivers exceptional strength and dimensional stability, a favorite for high‑tolerance applications.

3D‑printed injection molds are integral to Glassboard’s development process. The Form 2 and Form 3BL provide the versatility to prototype at scale, from single prototypes to large‑batch production molds.

Form 3BL: Expanding Horizons in Vacuum Forming

Glassboard has leveraged the Form 3BL’s large build volume to create vacuum‑forming bucks for complex, large‑scale parts—an approach that traditionally required multi‑section prints on a Form 2. This shift cut production time from days to a single overnight run.

Grant Chapman
“A 24‑hour cycle for vacuum‑formed parts—print overnight, cure in the morning, form and trim by day’s end—defines rapid prototyping for us.”

The Form 3BL’s Low‑Force Stereolithography technology also excels at printing many small parts simultaneously. In one project, the team produced 30 urethane mold prototypes overnight, eliminating the need for multiple Form 2 prints and streamlining the workflow.

Biocompatible Materials for Human‑Contact Products

Grant Chapman
“Access to skin‑safe materials transforms how we prototype touchable parts.”

Dental LT Clear V2 is a standout for biocompatible prototyping and mold making. Its mucous‑membrane safety, precision, and easy support removal make it ideal for parts that may contact skin or mucosal tissues. Transparent printing also allows visual inspection for defects during molding.

Reliability Drives Success

When iterating over 100 prototypes for Sunny’s applicator and cup, any printer downtime could jeopardize deadlines. Chapman emphasizes that reliability is about “not missing a print opportunity” rather than just downtime. Consistent uptime ensures that clients receive prototypes on schedule, maintaining trust and momentum.

Glassboard’s overarching goal is to prototype as quickly and efficiently as possible, testing in production‑like conditions before tooling is finalized. This approach reduces time to market and mitigates risk.

Future‑Ready 3D Printing

Chapman concludes, “3D printing is a tool I wish I’d adopted years ago. Its versatility and reliability make the Form 2 and Form 3BL central to every upcoming project.”

To explore how large‑format 3D printing can accelerate your product development, visit the Form 3L page or request a free‑sample part printed on the Form 3L today.