Reduce Downtime with Modular 3D Printed Components for Automation & Production Lines

Monday 15th June 2026

From warehouse automation and distribution centres to cosmetic filling lines and food production, one challenge remains the same: downtime and poor organisation costs money.

When a component fails on a production line, the knock-on effect can be significant. Waiting weeks or even months for replacement parts, holding expensive spare parts, or replacing entire assemblies because of one broken component, all adds unnecessary cost and disruption.

This is where Additive Manufacturing (AM) can offer a smarter approach.

Rather than replacing complete assemblies, 3D printing allows manufacturers to redesign components into modular sections, meaning only the worn or damaged part needs to be swapped out. The result? Faster changeovers, reduced downtime, lower costs, and components that are easier to adapt as requirements evolve.

Whether you operate in warehousing, logistics, packaging, cosmetics, food & beverage, or consumer goods manufacturing, Additive Manufacturing provides fast, practical wins.

Image: 3D printed puck inserts of different sizes with a master puck holder.

Why Modular Matters

Traditionally components are often designed as a “fully replaceable” i.e. if one clip snaps, one insert wears down, or one section changes size, the entire component will need to be replaced.

With AM, components can instead be designed around modularity and flexibility. This means:

• Only damaged sections are replaced
• Operating costs are reduced
• Components can be adapted quickly for new products
• Spare parts requirements are reduced
• Lead times shrink dramatically
• Reliance on external suppliers are reduced
• Changeovers become faster and easier

This approach works particularly well for conveyor parts, pucks and product holders, pushers and guides, stoppers and fixtures, sensor mounts and switch assemblies and bespoke automation components.

What’s more, as parts are 3D printed in just hours (or minutes), designs can continually evolve and improve based on real-world usage, through rapid iteration and testing.

Warehouse Automation: Redesigning a Switch Monitor Assembly

One large retail customer’s distribution centre was experiencing repeated failures with a switch monitor assembly used for automated product movement through the site.

The clips on the assembly would regularly snap during operation, rendering the entire assembly unusable. Each replacement assembly costs approximately £150, and multiple variants had to be held in storage to keep operations running.

Rather than continuing to replace the full unit each time, our CREAT3D engineers redesigned the component using Design for Additive Manufacturing (DfAM) principles.

The assembly was redesigned into modules, so that the clips become sacrificial and replaceable, not the entire unit. Printed in Nylon 12, using the Formlabs Fuse SLS 3D printing system, the retail customer was able to save costs and reduce downtime:

• Only the damaged clip is swapped out
• Components can be printed on demand
• Spare stock requirements are dramatically reduced
• Components can be adapted quickly for new products
• Warehouse storage space is freed up
• Waste is minimised

The cost reduction through using Additive Manufacturing was significant: Up to 80% cost saving

• Original assembly: £150
• 3D printed replacement: £30 printed in Nylon 12
• 3D printed single clip: Only 68p to replace the clip
• No minimum order quantities
• No tooling costs

Image Above: 3D printed switch motor assembly redesigned with replaceable clips.

Image Right: Switch monitor assembly: original version with redesigned 3D printed version

Cosmetic Production Lines: Modular “Russian Doll” Pucks

Another application that has been improved with Additive Manufacturing, are pucks within a cosmetic filling and packaging line.

In these environments, the size and type of packaging changes frequently, depending on the product running down the line. Traditionally, this means a requirement to hold a wide, and costly, array of different sized pucks. Typically, pucks are custom-milled inserts or trays designed to securely hold bottles or packaging that are too small, tall, or uniquely shaped (e.g., irregularly shaped perfume bottles) to travel safely on standard conveyor belts.

3D printing allowed the customer to rethink the component and its design.

Using the Formlabs Form 4L and Tough 1000 Resin, a modular puck insert system was developed, effectively creating a “Russian doll” puck arrangement.

A master puck remained fixed, while interchangeable inserts, designed to different shapes and sizes, allow the user to quickly adapt the master puck to the different packaging sizes.

This resulted in fast changeovers between lines, reduced costs and an exact fit for better functionality.

From Quick Fixes to Long-Term Improvements

Often, the best AM applications are not necessarily the biggest or most complex.

Take for example; a redesigned clip, a modular insert, a bespoke guide or a low-cost pusher. These smaller applications can deliver immediate operational improvements with minimal investment.

For manufacturers and automation teams, AM offers a way to:

• Reduce dependency on suppliers
• Adapt quickly to production changes
• Reduce operating and spare part warehousing costs
• Extend the life of existing systems
• Improve production rates with less downtime

What’s more, because components can be produced on demand, it becomes much easier to trial improvements and continuously adjust over time.

Looking for Quick Wins on Your Factory Floor?

From warehouse automation and conveyor systems to packaging and cosmetic production lines, AM is helping businesses reduce downtime, speed up changeovers, and lower costs with modular, production-ready tooling.

The best Additive Manufacturing applications are often the simplest — a redesigned clip, a modular insert, a custom guide or a low-cost replacement component.

If you have a part that repeatedly fails, requires regular replacement or slows your production process, our engineers can help you identify smarter, more cost-effective solutions. Send us a component, drawing or challenge and discover what's possible with Additive Manufacturing.

👉 Speak to our engineering team to to discuss your application or call 0800 689 1011.