From CAD to Calibrated Stamp in Days, Not Weeks: 3D-Printed Dies for Rapid Stamping R&D

When a manufacturer needs a new stamped part validated fast, before committing to hard tooling, the bottleneck is almost never the stamping itself. It's getting a die that's close enough to right to test against real specs, then iterating until it actually is right.

We recently ran exactly that process here at Altay Custom Plastics for a bimetal disc stamping application. A client needed a precise dent pressed into a metal disc to set a specific calibration point, and the part needed to hit tight dimensional targets before anyone would commit to production tooling for the new product.

3D print of the first die and punch for denting the disc.

The Problem: Calibration Is a Moving Target Until You've Tested It

The part in question, a thin bimetal disc, needed a dent stamped into it with a very specific depth and curvature. Get that geometry even slightly wrong, and the part's calibration point shifts. On paper, you can calculate a target profile. In practice, real material springback, thickness tolerances, and press behavior mean the first "correct" design on your screen usually isn't correct on the bench.

That's a bad problem to solve with steel tooling. Cutting a new hardened die for every guess gets expensive and slow, and this was still R&D, not production.

What We Built: 3D-Printed Upper and Lower Dies

Instead of machining, we designed and 3D printed a matched upper punch and lower anvil, a full die set sized to dent the disc to the target dimensions. Because the dies were printed, we could press a test part, measure it, and adjust the model quickly.

It took two to three design iterations to land on final geometry, tuning dent depth, curvature radius, and clearance until the pressed part matched spec. Each iteration was a fast turnaround: adjust, print, press, measure, repeat. That loop is where a printed-die approach earns its keep. It turns "how do we know this geometry is right?" into a question you can answer empirically in an afternoon instead of a design review.

Where AI Fits In: Parametric CAD That Moves at the Speed of Iteration

The other piece that made the fast turnaround possible was how the CAD itself was built. Rather than modeling each die revision from scratch, we set the geometry up parametrically from the start. Disc diameter, dent curvature, contact diameter, springback allowance, and clearance are all driven from a single parameter set that regenerates the full die model on demand.

We're now integrating AI directly into that CAD workflow to push this further. Instead of manually reworking geometry every time a measurement comes back out of spec, we can describe what changed (for example, "the dent came out 0.003 inches shallow") and have the parametric model adjusted and regenerated in the same session. The initial CAD pass for a new die design also comes together dramatically faster with AI assistance handling the first-pass geometry and parameter setup, so more of the iteration budget goes toward testing real parts instead of redrawing them.

The result is a design-print-test loop tight enough to treat physical validation as a normal part of engineering a die, not an expensive exception.

Why This Matters for Manufacturers Bringing a New Product to Market

If you're a manufacturer trying to get a new stamped component to market ahead of competitors, this kind of R&D-stage die work solves a specific problem. You need confidence in your geometry before you spend on hard tooling, and you need it fast.

We offer this as a time-and-materials engineering service at Altay Custom Plastics: rapid 3D-printed die design and iteration to validate stamping geometry, dimensional targets, and calibration behavior before you commit to production dies. You get tested, dimensionally proven geometry, plus a parametric model that's ready to hand off to a toolmaker, instead of a best guess.

Other Ways This Approach Helps Manufacturing Customers

A few other angles where this kind of rapid, printed-die R&D pays off:

• Bridge tooling for low-volume runs. If you need a few hundred parts to qualify a customer or run a pilot batch, a durable printed die set can sometimes produce short-run production parts directly, with no hard tooling investment until volume justifies it.

• De-risking multi-vendor sourcing decisions. Prove out geometry and process parameters in-house before handing specs to a stamping vendor, so you're negotiating from validated data instead of a drawing.

• Reverse-engineering and requalifying legacy tooling. When an old die is worn, lost, or undocumented, we can rebuild the geometry parametrically or from a sample part or drawing and validate it in printed form before cutting new steel.

• Fast DFM feedback loop. Because iteration is cheap, we can hand design teams real dimensional feedback on their stamped-part geometry early, while changes still cost nothing but a reprint.

• Competitive speed-to-market. In categories where being first with a validated part matters, cutting weeks out of the tooling-validation phase is a real competitive edge, not just a cost saving.

• A parametric "digital twin" of the die. Every project leaves a live, adjustable CAD model of the tooling, not just a finished part, so future spec changes or new disc sizes can be re-validated in hours rather than starting over.

If you're developing a new stamped product and want to validate geometry before committing to production tooling, this is exactly the kind of engineering support we provide at Altay Custom Plastics. Get in touch and let's talk about your part.

TempPro Cycle Testing

We are finishing up the second phase of our Senasys TemPro cycle testing. One of our customers engages us to automate cycle testing for several of their projects, and for this specific job we needed to reach 20,000 cycles on each unit to provide documentation of their conditions at that cycle count.

Neither we nor anyone else has the time to sit and push a button 20,000 times or to manually move a temperature probe in and out of a heated zone to confirm the unit’s function. With only 1,440 minutes in a day, a two-minute average cooling-and-heating cycle will max out at 720 cycles under continuous testing, and that would make the manual task take weeks of repetitive work.

To address this, we developed an automated system using a servo controller, sensing electronics, and custom software to drive the RTD sensing probe in and out of the hot area thousands of times. The system verifies the servo operation and hold locations, tracks the dwell time in each zone, and when the program detects that the part has either cooled or heated as expected, it logs the data and advances to the next cycle. After every 1,000 cycles we get an update email. For this particular report we will also disassemble the relays and photograph the contacts to document the system’s condition at the conclusion of testing. The automated emails and overnight allow us to monitor testing remotely and know we are operating as intended. Those updates are forwarded to the team contact so they stay fully informed throughout the testing campaign.

The swinging arm and limit switch towers are 3-D printed in house and designed to verify the mechanical systems function. Using the 3-D printing tools and electronics on hand, we have we can field test structures and built out the full testing space. Engineering and design is an iterative process and this helps us adjust the testing system to function over the long cycle times and diverse requirements.

Software Development

Using leading AI programing IDE’s and a designer that knows programming, we accelerate the software and logging of the cycle testing. By using the AI IDE's we cut the software development time down and compress and resolve errors before they impact testing. The other components for servico control and operations are also intelligently designed so cycle counts and other items can adjusted quickly from config files and well organized. This allows us to easily customize the output reports and generate and track all the necessary information for your QA processes.

Hardware Development

With every cycle testing system the other half of its functionality arises from the mechanical system. Even though we were using a heat zone, 3D printed plastics and armature worked excellently for this use case as the heat zone was relatively small and the radiative cooling of the plastic was enough to keep it cool to the touch even while it was heating. Selecting servos and other items to move the necessary components went quickly and allowed get the utility out of the system quickly and keep costs for the entire process low. There is value in aestheticly pleasing automation systems, but for a cycle test that is used only a handful of times creating a modular solution was more important. We can use the servo mount and limit switch towers again for other types of testing. If it needs to be set back up we have the components and layout.

with otherWith other systems that may become more permanent automations for customers, The in house CAD development and layout allows this iterative design process to occur quickly and large print formats make it easy to make the prints in one component versus multiple components. With our printers we operate webcams to view remote operation and This feature could be added for any cycle testing or other testing for remote monitoring as well.

TemPro Cycle Testing Setup

Give us a call to get a quote on a cycle testing system and assistance for cycle testing your projects.

Why Does My Tesla Smell Musty? The Cabin Air Filter Drain Hole Fix You Need

If you've ever stepped into your Tesla Model 3 or Model Y and caught a whiff of something musty, damp, or mildewy — you're not alone. It's one of the most common complaints in Tesla owner forums, and the frustrating part is that replacing the cabin air filter often doesn't fix it.

So what's really going on? And more importantly, how do you fix it for good?

The Real Reason Your Tesla Smells Musty

The cabin air filters in the Model 3 and Model Y sit in the HVAC intake area beneath the windshield. When the air conditioning runs, condensation naturally forms and is supposed to drain away through a designated drain hole at the bottom of the filter housing.

The problem? The bottom cabin filter can sit flush against or directly over this drain hole. Moisture accumulates instead of draining, the filter stays wet, and bacteria and mold start to grow — creating that musty, unpleasant odor that no amount of air freshener seems to fix.

Does Replacing the Cabin Air Filter Fix the Smell?

Partially — and temporarily. A fresh cabin air filter will smell better for a while, but if the underlying moisture issue isn't addressed, the new filter will develop the same problem within weeks or months. Many Tesla owners report going through multiple filter replacements chasing the same recurring smell.

The permanent fix is to stop the moisture from pooling in the first place.

How the Cabin Air Filter Clip Solves the Problem

The Tesla Model 3/Y Cabin Air Filter Moisture Clip is a small 3D-printed bracket that attaches directly to the bottom cabin air filter, positioned 4.25 inches from the tabbed side. It creates a gap that keeps the filter from sitting directly over the drain hole, allowing condensation to drain freely as it should.

The result is a drier filter, a cleaner HVAC system, and a cabin that smells fresh — even after months of use.

What Material Should the Clip Be Printed In?

PETG is the recommended material. It's more flexible than PLA, which means it won't crack when you clip it onto the filter, and it has a higher heat tolerance — important for an accessory that lives in the engine-adjacent filter housing during hot summer months.

PLA can also work if your Tesla has cabin overheat protection enabled, which keeps interior temperatures from getting extreme. But for most climates and use cases, PETG is the better choice.

Is This Compatible with My Tesla?

Yes — this clip is designed to fit both the Tesla Model 3 and Model Y across all trim levels and production years. Both vehicles share the same HVAC filter housing design, so one clip fits all.

How Hard Is It to Install?

Very easy. No tools required. The clip attaches directly to your existing bottom cabin air filter before you slide it back into the housing. The entire process takes just a few minutes, and can be done at the same time as a regular filter replacement.

Why Buy a Printed Clip Instead of Printing It Yourself?

The design is freely available on Printables.com, and if you have a 3D printer, you're welcome to print it yourself. But for those who don't own a printer — or who want a ready-to-install solution without the hassle — ordering a pre-printed clip means you get a correctly oriented, quality-checked part that's ready to go the moment it arrives.

Printing orientation matters here: the clip needs to be printed on its side to ensure the tab has maximum strength. Getting that right on a first print isn't always guaranteed, especially for those new to 3D printing.

The Bottom Line

That musty Tesla smell is a known, fixable issue — and the fix is simpler than most owners realize. A small 3D-printed clip, properly placed, solves the drainage problem that replacement filters alone can't address.

If you're tired of chasing the smell with air fresheners and filter swaps, this is the upgrade your Tesla's HVAC system actually needs.

Future of STEM Education: Build Scale Model Storm Sewer Systems

In a world where understanding the intricate systems of our cities is vital, developing a scale model storm sewer pipe and manhole kit is an innovative and crucial educational tool. Aimed at teachers and individuals between the ages of 10 and 30, this upcoming creation is poised to revolutionize how we learn about storm utilities in urban environments.

Combining the elements of fun and education, this toy is not just a plaything but a hands-on, interactive means to grasp the basics of stormwater management and how these systems operate within our cities. Designed to be watertight, this miniature sewer model will replicate the workings of real storm utilities, showcasing the movement and management of water during heavy rainfall and storms.

Why STEM Education Matters:

STEM (Science, Technology, Engineering, and Mathematics) education is fundamental for fostering innovation, critical thinking, and problem-solving skills. It provides a gateway to understanding complex systems and encourages the pursuit of solutions to real-world problems. Integrating STEM concepts into educational tools makes learning engaging and applicable.

The Journey Towards Development:

The creation of this scale model storm sewer and manhole toy is a collaborative effort between educators, engineers, and designers. Our team of technical professionals and registered engineers aims to make the learning experience both informative and enjoyable, allowing students and enthusiasts to comprehend the role and function of storm utilities in urban infrastructure.

The toy's design emphasizes accuracy, ensuring that the mechanisms of stormwater movement within cities are effectively represented. Its watertight construction enables users to simulate and observe the flow of water, replicating scenarios of heavy rainfall and demonstrating how these systems manage excess water to prevent flooding.

Understanding Urban Infrastructure:

It is important to understand the complex networks of storm utilities that cities rely on to channel excess water away from streets and buildings. Teaching the fundamentals of these systems is crucial, especially given the increasing impact of climate change, which has led to more frequent and intense storms.

The scale model storm sewer system provides a tangible and visually stimulating way to comprehend the function of storm utilities. Through hands-on interaction, users can gain insights into the importance of maintaining these systems, highlighting their role in mitigating floods and preserving urban landscapes.

Empowering Future Engineers and Innovators:

By engaging with this educational toy, individuals are exposed to the principles of engineering, hydrology, and urban planning. Encouraging an early interest in these fields can spark curiosity and potentially inspire the next generation of engineers and innovators. It also instills a sense of responsibility toward environmental stewardship and infrastructure maintenance.

The forthcoming scale model storm sewer system represents an exciting leap in educational resources by ALTAY Custom Plastics. Its focus on STEM concepts, particularly engineering and urban infrastructure, aligns with the growing need for innovative teaching tools that prepare the future workforce for the challenges of a rapidly evolving world.

By providing a captivating and informative experience, this toy serves as a gateway to understanding the essential role of storm utilities in cities. It not only educates but also inspires a new generation to tackle the complexities of urban infrastructure and environmental sustainability.

Stay tuned for the release of this educational masterpiece, poised to revolutionize the way we learn about storm utilities and propel STEM education into a new realm of interactive discovery and understanding.

How Photogrammetry Can Enhance Product Development and Research

Photogrammetry is a technique used to capture and combine measurements from photographs. These measurements are used to create detailed 3D models of objects. Photogrammetry has many uses, but one of the most common is in the field of product development and research. In this blog post, we’ll explore how photogrammetry can enhance your own product development and research process. We will explore how photogrammetry can help you streamline your process, reduce time spent on research and documentation, improve collaboration across teams, and even allow you to create new experiences for your customers—all while maintaining optimal security.

What is Photogrammetry?

Photogrammetry is the science of making measurements from photographs. A photogrammetric surveyor uses this method to take measurements from photographs. These measurements are used to create a 3D representation of a real-world subject.

Photogrammetry can be used to do accurate surveying as well as to create 3D models of objects. It is also used in many other fields like architecture, engineering, archaeology, robotics, film, and animation.

The word “photogrammetry” is made up of two Greek words, “photon”, which means light, and “metron”, which means measurement.

Light travels in straight lines. Instead of measuring the distance from a single point to an object and trying to find the intersection of those lines, photogrammetry uses light to form a 2D image of the object.

The photogrammetric process starts with the acquisition of images. Once you have your images, you need to use photogrammetric software to process them. This software will create a 3D model of your object.

Why Use Photogrammetry for Product Development?

As digital marketing continues to evolve, companies are increasingly turning to virtual reality and augmented reality to engage their customers and potential customers. Virtual and augmented reality is rapidly changing how we design and engineer products and will play a large role in the future of product development.

The primary reason for using photogrammetry for product development is that the technology results in high-quality 3D models. These detailed models can be used to create virtual and augmented realities. Combined with other technologies like AI and blockchain, photogrammetry makes it possible to automate many of the manual tasks associated with product development. With more automation, engineers and designers have more time to focus on innovation.

Benefits of Photogrammetry in Product Development and Research

Since photogrammetry relies on pictures as its source data, you can capture your data from a variety of different sources. You can use drones, satellites, robots, or even people with cameras. This flexibility allows you to capture data in any environment or situation. You can even use photogrammetry to recreate the inside of a customer’s home.

Because there is no need to manually record measurements, photogrammetry makes it faster and easier to create virtual or augmented reality. It will also reduce the margin of error significantly.

Create New Customer Experiences

Virtual and augmented realities built with photogrammetry give customers an immersive experience. These experiences are highly precise and accurate. Because these realities are created from pictures, they are also very realistic.

Companies can use photogrammetry to create lifelike customer experiences that are impossible to create with traditional methods like print, packaging, and websites.

For example, you might create a virtual reality for customers who want to try out a new couch before buying one. Or you might create an augmented reality that shows customers how their new car will look inside and outside.

Reduce time spent on documentation and research

With photogrammetry, you don’t have to record measurements manually. This reduces the margin of error and allows designers and engineers to spend less time on documentation. Photogrammetry also makes it easier to create 3D models of real-world objects. This makes it easier to research and design something before it is actually built.

For instance, before designing a new car, engineers use computer-aided design (CAD) software. But this software isn’t accurate enough to create a virtual reality or a lifelike model of the car. Using photogrammetry, engineers can create digital mock-ups of the cars with realistic materials and textures.

Conclusion

Photogrammetry is a powerful technology that can be used in a variety of industries for a variety of different uses. It can be used to create extremely accurate 3D representations of people, buildings, and even objects.

It can also be used to create lifelike virtual and augmented realities. And it can do this without the need for specialized equipment like cameras or other heavy machinery. All you need is a smartphone and the right software.

But that’s not all. Photogrammetry can also be used to create more streamlined product development processes. It can also be used to create new customer experiences and reduce the time spent on research.

Need unique photogrammetry services for your next project? Get an estimate below or check out our shop for pricing.