Dinsmore, an ADDMAN Group company, is a leading service bureau specializing in additive manufacturing. Known for its expertise in low-volume industrial, electromechanical, and healthcare solutions, Dinsmore continually seeks new technologies to push the boundaries of what is possible in precision manufacturing.

This case study highlights how Dinsmore overcame a significant manufacturing challenge—producing intricate medical stent cores at an actual, functional scale—by integrating Axtra3D’s Lumia X1 into their workflow.

Challenge: Micro-Scale Precision for Medical Applications

Producing highly intricate geometries at a micro-scale posed a major challenge for Dinsmore, particularly in the medical sector. Stent cores, critical components in cardiovascular and other medical applications, required extreme precision, thin walls, and durability to survive secondary coating processes.

For years, Dinsmore could only manufacture scaled-up visualization models due to technology limitations, forcing them to turn down requests for production-scale stent cores. The lack of an additive manufacturing solution that could handle such delicate structures without failure created a gap in their service offerings.

Solution: Implementing the Lumia X1 for Micro 3D Printing

Dinsmore adopted Axtra3D’s Lumia X1, a hybrid SLA-DLP 3D printer, to overcome these limitations. The printer’s laser and digital light processing (DLP) hybrid system provided:

• High-resolution micro-scale printing for intricate geometries
• Dual and single polymerization modes that automatically switch based on cross-section complexity
• Unmatched stability—unlike traditional SLA/DLP systems, the Lumia X1 prints upside down, preventing delicate structures from collapsing
• Advanced support control through Volume software, allowing for precise customization of supports to ensure structural integrity

This combination enabled Dinsmore to successfully print medical stent cores at actual scale, something previously unattainable.

Results: Breakthrough in Medical Stent Manufacturing

The integration of the Lumia X1 immediately expanded Dinsmore’s capabilities, allowing them to:

• Produce medical stent cores at functional scale with the required thinness and strength
• Ensure high precision within 20 microns of accuracy, critical for medical applications
• Eliminate the need for oversized visualization models, offering true-to-form production parts
• Minimize material waste, as all materials are reusable after printing

While specific cost savings metrics remain proprietary, the efficiency gains, improved throughput, and reduced waste provided clear economic advantages.

Expanding Opportunities with the Lumia X1

Beyond medical stents, Dinsmore has leveraged the Lumia X1 to broaden its material portfolio with applications in ceramics, industrial components, and functional prototyping. The printer’s open-access material ecosystem has allowed for experimentation with materials like BASF 3280 Ceramic, Spot A Functional, and 3DS Med-Wht 10, providing customers with a diverse range of manufacturing solutions.

Expert Insight from Dinsmore

Kirill Tulinov, the primary lead for this project, shared his thoughts on the Lumia X1:

“As someone who likes to push machines to their limits, I was genuinely surprised by Lumia’s performance. It has been a true plug-and-play experience out of the box.”

He further noted:

“I didn’t know over an inch of an unsupported bridge was possible. Lumia presents the best combination of print area, accuracy, surface finish, resolution, print throughput, and ease of use among all SLA, DLP, and LCD systems available.”

Conclusion: The Future of Micro 3D Printing at Dinsmore

By adopting Axtra3D’s Lumia X1, Dinsmore has redefined what’s possible in micro 3D printing. Their ability to manufacture ultra-precise medical stent cores at functional scale has opened new opportunities in the medical sector and beyond.

The seamless integration of the Lumia X1 into Dinsmore’s workflow has not only expanded their service offeringsbut has also positioned them as a leader in high-precision additive manufacturing.

For companies requiring next-level precision, reliability, and scalability in micro-scale 3D printing, Dinsmore and Axtra3D’s Lumia X1 represent a new industry benchmark.