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We saved 10k per part tooling Ovafly for additive production vs molten plastic aluminium casting.


Sustainable Manufacturing Solutions

Medium to Large Scale Production

Reduced Dependence on Overseas Supply Chains

Cutting-Edge Additive Manufacturing

Who We Are

We specialise in design for sustainable additive manufacturing. Our innovative and sustainable 3D printer manufacturing process offers a route to medium scale plastic production, easing our dependence on overseas manufacturing supply chains and creating new opportunities for early stage ideas. In prototyping or industrial scale production, we provide solutions for the entire manufacturing process.

Why Choose Sustainable Additive Manufacturing Design?

Customized Manufacturing Solutions

At, we believe that every design is unique and requires a customized approach. Our industry experience provides bespoke service that ensures every customer receives the best possible solution for their needs.

Sustainable and Durable Materials

We use only the highest quality, sustainable materials to ensure that our products are environmentally friendly and built to last. Our materials are rigorously tested to ensure durability and performance.

Cutting-Edge Additive Manufacturing Technology

Our state-of-the-art compartmentalised printer manufacturing process is at the forefront of the additive manufacturing industry. We are constantly innovating and improving our technology to provide our customers with the best possible solutions.

Expert Design

Our team of experienced advisors is here to help you every step of the way. From initial design to final production, we provide guidance and support to ensure that your project is a success.

CPM Production


"Their ability to transform conceptual ideas into functional and visually stunning designs truly set them apart in the industry."
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Jeremy Hyde

Finance, FD & CFO Centre.

"I am thrilled to share my experience working with TNS. As an advisor of innovative and impactful design solutions, I was consistently impressed by the agency's unparalleled creativity."
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Gary Parker

Director, EY Incentives.

"From our initial consultation to the final delivery of the project, Lewis demonstrated a deep understanding of industrial design principles and a passion for pushing creative boundaries."
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Paul Harrison

Paralegal, IP21.

Our Design Portfolio

Our Clients

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  • What material should I use for printing?
    I would start with PLA+ when you are first beginning a 3d print setup. Use a 0.4mm nozzle and set your layers at 0.2mm high. Print speed at 60mm/s and a printing temperature of 220 degrees celsius.
  • Which printer should I buy my son/daughter for Christmas?
    Start with the Creality Ender 3 series which is a great introductory machine for beginners.
  • Where can I buy materials for my 3D printer?
    Sunlu, 3d Jakes, Esun, Filamentive and Spectrum are all recommended suppliers of PLA+ and PETG
  • How can I design my product for CPM production?
    The following are modules we offer on the design for CPM process: Product Development - Convergent sketch ideation - Drawing in two-point perspective - Using cure colour pens to add form to sketches - Divergent modelling using CNC Router and laminated Foam Board - Drawing in illustrator and exporting sketches to ugs platform/universal g-code sender - Calibration of CNC mill - Printing 2d drawings and laminating onto plywood to use as stencil for modelling - Extrusion of model schematics into Fusion 360 and conversion to parametric forms - Saving from illustrator into dxf. file - Opening DXF in Fusion 360 and extruding out the model within physical model parameters - Using chamfer and fillet tools to round off corners and create ovular forms - Compartmentalisation of form, orientation for printing with supports and creation of male/female connectors. - Slicing the model into sub-components with reference to slicing orientation - Drawing sketches onto the model - Extruding male connectors and cutting female connectors - Slicing models to gcode for PLA print export. Inside wall thickness and infill. Layer height and bed levelling. - Exporting to Cura and changing the normals to smooth form - Calibrating the print in Cura and changing inside wall thickness and infill density - Print supports and brimming - Transition to PETG printing of components - Choosing the right PETG materials - Where to get them from - Minimising waste through inevitable print failures and recycling the waste - Testing of concept and continual improvement towards simplicity/complexity - Filming the model’s performance using high-speed camera - Analysing points of failure and improving the model in Fusion - Production of prototype with hexadecimal colour wrapping - Assigning materials to the model and rendering for visual approval - How to extract a colour pallet from an abstract photograph and determine hexadecimal code.
  • How fast is CPM and what is the lead time?
    In a facility housing 200x 3D printers, we can produce 10,000 Ovafly components per week but this is a 38 component library with a 54 stage assembly process. A product combining 5 'clothes peg' sized components could be produced in mass manufacturing numbers; circa 19,200 parts per day or 96,000 parts per week. That's 384,000 parts per month and 4,608,000 parts per year.
  • How is 3D printing better than injection moulding?
    CPM production is a 'pull' system whereby we are only producing what the customer is ordering. Sure, an injection moulding facility can produce high-high volumes in one day, but the initial tooling cost is 90% greater and how many of those components are sold straight away? How long would it take to box those components up and how long would it take to ship them around the world? This is the Tortoise vs the Hare, and its about looking at the supply chain as a whole. If you were to have a race between the two, we would get our products to our customers much faster and much cheaper. It's time to end inflation through customs and handling charges associated with overseas shipping and bring it all back to UK shores.
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