cotu s.r.o.: SLA 3D printing of large-volume Kofola crates in record time

When the team at Kofola approached cotu^® with a request for the rapid production of a presentation crate, it was clear that this would be a project testing technical skills, precise planning, flawless printing and the ability to come up with a smart design solution.

The brief was clear: Create a large model of a plastic crate for presentation purposes that would match the original not only in dimensions, colour and surface quality, but also in its sharp edges and fine details.

The only catch? There were just seven days to complete the project, during which four units had to be produced. Given this tight schedule, printing continued uninterrupted even over the weekend so that the order could be delivered on time without compromising quality.

As the dimensions of the crate model exceeded the build volume of the SLA printers, its design had to be modified and divided into smaller parts. The design had to be optimised for 3D printing so that splitting it into multiple parts would not affect the final accuracy, functionality or quality. It was also important that, after bonding and painting, the joint would disappear completely and the surface would appear to be made from a single piece, even on close inspection.

How cotu Decided to Tackle This Challenge

Technology used: Phrozen Sonic Mega 8K
Material used: Ultracur3D^® RG 1100

Splitting the Model and Preparing the Data

In the first phase, cotu^® began modifying the digital model. To enable the individual parts to be printed to the required quality, the entire model had to be divided into four segments. The key to trouble-free assembly after printing was above all the smart design of the parting planes. To ensure smooth assembly, the cotu^® team designed a so-called puzzle structure, which ensures precise alignment of the individual parts without the need for additional milling or machining.

The model was processed in Materialise Magics software, where it was split into individual parts, followed by the precise generation of print supports and parting planes. The model was modified to make 3D printing as fast as possible and reduce material consumption to a minimum.

3D Printing with Ultracur3D^® 1100 on Phrozen Transform

For the actual production, they chose the proven Phrozen Transform SLA 3D printer, which enables larger objects to be printed at high resolution. Printing used Ultracur3D^® RG 1100 material with a layer thickness of 100 µm, which made it possible to achieve:

• high dimensional accuracy,
• smooth surfaces without unnecessary additional sanding,
• sufficient mechanical strength for handling and assembly.

To meet the demanding deadline, the print layouts were designed to enable parallel printing of multiple parts and make maximum use of the available build area. Special attention was also paid to the crate handle, which was likewise divided into several parts for efficient printing and easy assembly. Once all the parts had been printed, careful manual post-processing followed - support removal, bonding, filling and final painting in precisely defined shades, so that the finished appearance of the crates would meet Kofola's high presentation standards.

What the Project Put to the Test and What Worked Flawlessly

The 3D printing process proceeded without any complications thanks to the long-proven combination of the Phrozen Transform 3D printer and Ultracur3D^® RG 1100 material, which demonstrated reliable results even on projects involving large volumes. Precise preparation in Magics software enabled efficient model splitting and support preparation, which facilitated assembly and ensured reliability and shape accuracy. This significantly accelerated the entire process.

Given the time pressure, all production stages had to be made as efficient as possible. Data preparation, 3D printing of the individual segments and subsequent assembly therefore ran concurrently using three 3D printers according to a precisely defined schedule. Any delay could have jeopardised the completion deadline, but thanks to careful organisation and the well-coordinated cotu^® team, the model was delivered to the required quality and on time.

Summary of the Project's Success

The order for Kofola confirmed that the right combination of 3D printing, technical expertise and an efficiently configured process makes it possible to achieve an outstanding result even with severely limited time for completion. By optimising the workflow, cotu^® ensured the delivery of complete crate models in the required colours, to a high standard of quality and with a high-quality surface finish.

The finished crates were ready on time for presentation at a press conference for journalists and the media. This project also confirmed that SLA technology is a reliable solution not only for functional prototypes, but also for high-quality presentation models, where precise detail and aesthetic execution play a crucial role.

Looking for a Reliable and Precise Solution That Performs in Practice?

Whether you need to design functional prototypes, fine-tune a design or arrange small-batch production without unnecessary costs, the cotu^® team will give you confidence at every stage of development. Rely on an experienced partner who will turn your vision into a functional and aesthetically pleasing result.
Quickly, to a high standard and with the utmost care.