Dunlop Systems Accelerates Tool Production with Markforged 3D Printing

Mark Statham, Production and Engineering Manager at Dunlop Systems and Components, identified a persistent bottleneck: the tooling team had to wait weeks for replacement parts, either by fabricating them in‑house or outsourcing to third parties. The delay stalled production and raised costs.

Seeking a Faster Solution

Statham heard about Markforged’s continuous‑fiber 3D printers at a Mark 3D event. The printers could produce strong, durable tooling with on‑demand flexibility. “When I saw what the printers could do, I immediately asked if we could build our own tooling,” he recalled.

Adopting Markforged Desktop 3D Printing

After an internal review, Dunlop invested in a Markforged Composite Desktop series printer. The transition was transformative. “Before the printer, new tooling was sparse and disposable—once a customer requested a change, the prototype was discarded,” Statham explained. “Now we can iterate quickly and afford to print each part as needed.” Lead times dropped from weeks to one or two days.

Real‑World Impact

Key tools, such as a hydraulic‑crimping fixture for air‑suspension components, were initially made from nylon but warped in hot summer conditions. The team replaced them with Markforged Onyx, a material that resists heat and retains dimensional stability. This shift reversed the supply chain: tooling is ready before parts arrive.

Annual savings are projected at £40,000 (≈ $50,200) from reduced outsourcing and faster turnaround.

Supporting Innovation in Electric Vehicles

The printer also produces custom tooling for a beta electric‑vehicle prototype. Previously, the company spent thousands of pounds on outsourced tooling. For example, a piston that would normally cost £500 (≈ $630) to fabricate now costs only £15 (≈ $18) to print. “We no longer say ‘we can’t do it’; we say ‘we can do it, let’s explore how to print it,’” Statham said.

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