A versatile handle for a breaching tool, for Sun Hi-Tech

We developed the handle for Sun Hi-Tech, who specialise in producing breaching equipment for security and rescue forces. After a design brief from the project manager we set off, and went through a relatively short development process of three months.

The project called for answers to a range of problems, the most important of which was how the product is used: it had to stay simple and quick to operate.

Over the course of the project we produced many models before arriving at the final one. In the end we decided to make the finished product by 3D printing, for several reasons:

1. The small number of parts we were asked to supply, up to 50 units.

2. The client’s requirement for a relatively short timescale.

3. The option to change the product later without going into a new development cycle.

The technology and the material

The project was produced in MJF – Multi Jet Fusion, nylon powder printing. The part is built layer by layer inside a powder bed, with no supports, and the whole build volume is available for parts. That is what makes the technology suit small runs exactly: the chamber can be filled with dozens of different parts in one build, with no dedicated tooling to pay for.

The material is nylon 12 (PA12) – an engineering material with good mechanical durability, dimensional stability and an even matte finish. See more on choosing a material.

What settled the decision

A breaching tool is used with force, usually in gloves and under time pressure. In design terms that means the handle needs a certain grip even when wet, and must not add a single extra step to operate. That is why we made model after model and tested them in the hand before settling the geometry – which is exactly the advantage 3D printing gives in development.

Why we chose 3D printing

Small quantity – tens of units, not thousands. An injection mould does not pay for itself at that volume.
Timescale – days to weeks, rather than months for tooling.
Room to change – the file can be corrected and a new version printed without starting development again.
Geometric complexity – shapes that cannot be milled or cast come straight off the printer.

A similar project of your own?

Send us a file or a description of the problem and you will get a recommendation on technology, material and timescale – talk to an engineer. See also product design and development and 3D printing production.