From idea to 3D printed part: how a custom part gets made

"Can you make this part?" is one of the most common questions we get. Sometimes it arrives with a CAD file. More often it's a photo of a broken bracket, a sketch on graph paper or "something like this, but bigger." All of those are fine starting points.

Here's how a custom plastic part goes from idea to something in your hand.

1. Tell us what you need

The more of this you can share, the faster we can quote:

• A file, a photo or a sketch. STEP or STL is ideal. A clear photo with a ruler in frame and a few key measurements works too.
• Quantity. One prototype, ten spares or a few hundred parts call for different processes.
• Where it will live. Indoors or outdoors? Near heat? Under load? Touching food, fuel or chemicals?
• Timing and finish. When you need it, and whether color or surface finish matters.

Send it through the quote form. Mention that you have files and we'll reply with a secure way to share them.

2. Design or check the model

If you already have a CAD model, we review it for printability: wall thickness, overhangs, hole sizes, and how the part will be oriented on the printer, which affects strength.

If you don't, our engineering partners create one. For a broken or discontinued part that means measuring the original and reverse engineering it, often improving the weak spot that made it break in the first place. For a new idea it means a concept, a first model and a conversation about trade-offs.

3. Pick the right material

Material choice matters more than most people expect. A quick guide:

We'll recommend one based on what the part has to survive, not just what's cheapest.

4. Prototype, test, adjust

For anything that has to fit or move, we start with a prototype. You check it against the real assembly: does it clip in, line up and hold? Small changes at this stage cost almost nothing. The same changes after a production run cost a lot.

5. Make the real thing

Once the design is right, we produce the parts with the process that fits the quantity:

• 3D printing (FDM or resin) for one-offs and short runs, with no tooling cost.
• Nylon powder printing (SLS) for strong, complex parts in small batches, through our partners.
• CNC machining or injection molding when volume, strength or material calls for it, also through our partner network.

Finishing (sanding, painting, inserts, labels) and assembly can be added when needed.

6. Delivery, and the files are yours

Parts are checked before they ship. You also get the final model files, so you're never stuck if you need more later.

When there's software involved too

Plenty of part projects come with a software side: an enclosure for a sensor that needs a dashboard, fixtures for a line that needs a work-order tracker, replacement parts that need an inventory app. Because TrussCode builds software as well, it can be one project, with one quote and one point of contact.

Have a part in mind? Get a parts quote or read more about custom 3D printing and engineering.