Aprios Archive

White Paper: Designing the Previously Impossible Parts

Written by Nick Erickson | Dec 8, 2025 10:07:00 PM

Aprios, a custom injection molding company and additive manufacturing company specializing in high-precision components, has released a new white paper titled Design and Manufacture the Impossible. This white paper details how Carbon® Digital Light Syntheses™ (DLS™) technology allows engineers and manufacturers to explore what has been previously impossible to produce using conventional manufacturing. Some of the design possibilities discussed include articulating structures, sharp corners, complex lattices, consolidation of multiple components into one, new surface textures, and more.

Many new product designs and innovations have been restricted by the limitations of plastic injection molding services and other conventional manufacturing processes. This white paper shows engineers how Carbon DLS Prototyping technology transforms product design and production with advanced design for manufacturing solutions.

Unlike other traditional 3D-printing technologies, Carbon DLS is not just for prototyping. Engineers can now design complex end-use parts that can be manufactured, without tooling, in small- to large-volume production runs. This means industries can take advantage of Custom Injection Molding Solutions, Rapid Prototyping Services, and Low-Volume Injection Molding to accelerate product launch and scalability.

The white paper discusses the use of generative design tools, which help engineers transcend the limits of traditional design. Learn how geometries, lattices, and materials can be optimized to meet specifications for strength and durability while reducing overall weight. This approach aligns with both Plastic Part Design Optimization and Design for Additive Manufacturing (DfAM) principles.

Also, discover how to take products to the next level with each part customized to user-specified parameters. Additionally, the white paper highlights how engineers can boost quality, strength, stiffness, heat dissipation, and performance while leveraging additive manufacturing services and precision manufacturing services.