30-Day Lead Time Reduction & Over $40,000+ in Net Savings: SuperATV’s Success with the Raise3D RMS220

Application Overview & Challenges

Operating in the highly competitive powersports aftermarket, SuperATV must rapidly develop products for newly released UTV and ATV models while ensuring every component meets demanding performance requirements such as high part strength, dimensional stability, impact resistance, and temperature resistance. Because many application-specific designs are frequently customized to accommodate different vehicle platforms and performance requirements, engineered parts often undergo multiple design iterations before production, making development speed a critical requirement.

Traditional machining methods presented several challenges during the development process:
• Each design revision increased machining costs and slowed the iteration process.
• Producing multiple prototype variations simultaneously was both expensive and time-consuming.
• Complex geometry optimizations are difficult or cost-prohibitive to manufacture conventionally.
• Lead time for replacement parts can stretch from several days to a week.
• Engineering teams required an in-house solution capable of producing durable, functional prototypes quickly while reducing dependence on external manufacturing.

Solution

To accelerate product development, SuperATV integrated the Raise3D RMS220 SLS 3D printing system into their engineering workflow, utilizing PA12 powder to manufacture functional prototypes and production-ready engineering components.

Unlike conventional machining, the RMS220 enabled engineers to move directly from CAD models to physical parts within hours, dramatically shortening the design-validation cycle. Typical builds required approximately 12 hours while producing up to 16 functional parts in a single print, allowing multiple design concepts to be evaluated simultaneously rather than sequentially.

The mechanical properties and dimensional accuracy of SLS-printed PA12 provide SuperATV engineers with durable, functional parts suitable for fitment checks, assembly validation, and performance testing. The powder-bed fusion process also enables complex internal geometries, lightweight structures, and integrated features that can be difficult or costly to manufacture using conventional machining. This design freedom allows engineers to optimize components specifically for additive manufacturing while consolidating multiple features or components into a single part.

By combining PA12’s functional performance with the RMS220’s design flexibility, SuperATV can move beyond basic visual prototypes and produce parts that more closely represent their intended application. Engineers can rapidly modify, print, and validate customized UTV and ATV components in-house, reducing the machining, tooling, and assembly requirements associated with traditional manufacturing. The ability to produce multiple design variations within a single build further streamlines fitment and functional testing, allowing engineers to evaluate and refine designs more efficiently.

Results

Following the implementation of the Raise3D RMS220, these capabilities have translated into measurable improvements across SuperATV’s engineering and product development workflow. Bringing SLS production in-house has reduced reliance on conventional machining and external manufacturing, providing faster access to functional prototypes, tooling, fixtures, and low-volume production parts.

Key results from adopting the Raise3D RMS220 includes:
• Reduced lead time by 30 days.
• Over $40,000+ in prototyping cost saved since deployment of the RMS220 within 2 months.
• Reduced tooling investment, inventory requirements, and prototype costs.
• Accelerated engineering validation through rapid in-house design iterations.
• Quicker turnaround for different designs.
• Enabled greater design freedom through lightweight, optimized geometries that are difficult to manufacture conventionally.

Future Outlook

As SuperATV continues expanding its engineering and manufacturing capabilities, industrial SLS printing has become an important component of its product development strategy. The Raise3D RMS220 enables engineering teams to rapidly prototype, validate, and refine new products entirely in-house, reducing development costs while accelerating time-to-market.

Looking ahead, SuperATV plans to further leverage additive manufacturing for functional tooling, production fixtures, end-use specialty components, and low-volume manufacturing applications. Combined with its vertically integrated design, testing, and manufacturing operations, industrial 3D printing will continue to support the company’s mission of delivering innovative, high-performance aftermarket products that are engineered, tested, and built to withstand the toughest off-road environments.