Custom production of representative awards for Škoda Auto using high-detail 3D printing by cotu s.r.o.

Custom production of prestige items for global brands places high demands not only on visual appearance, but above all on technical workmanship, production repeatability and long-term structural stability. This is precisely the type of project that cotu^® carried out for the agency UGO! Media, which was arranging the production of awards for its client – Škoda Auto.

Project Brief

The aim of the project was to create an original and prestigious award for the winners of the individual categories in Škoda Auto's internal awards. The awards were to reflect the brand's corporate colours (Emerald green and Electric green), convey a luxurious impression and be structurally ready for series production with easy personalisation.

The client supplied a drawing and design proposal, on the basis of which cotu^® provided:

• complete 3D modelling,
• selection of the manufacturing technology,
• structural optimisation for stability and simplified repeat production,
• final production and assembly.

The order also included a version intended for an international market, which differed in its colour scheme.

Technical and Production Objectives

The main technical and production objective of the project was to design an award meeting the premium standards of a global car manufacturer, both in terms of appearance and workmanship. A key requirement was high surface quality with no visible traces of the manufacturing process, even under close examination of the finished product.

The structural design also had to ensure sufficient mechanical stability even with the inclined geometry of the award body, which places increased demands on weight distribution and the balance of the assembly. Another important aspect was preparing the design for series production with minimal differences between individual pieces, so that consistent quality could be maintained over the long term.

Structural optimisation also included addressing the mounting of the acrylic plates. We designed a mechanical snap-fit system, which eliminates the need for bonding or additional alignment during assembly. Each plate features a milled groove, while a precisely matched protrusion is integrated into the award body. This combination allows the plate to slide into a precisely defined position and remain firmly secured at the required angle.

The result is high mounting precision, significantly simplified assembly and reduced production costs while maintaining the highest visual and structural quality of each piece.

The brief also required achieving a visual effect imitating glass for the acrylic elements. The overall impression of the award therefore had to be neither lightweight nor plastic-like, but rather solid and valuable, in keeping with the character of the award.

Technologies and Materials Used

Technologies

• 3D printer Phrozen MEGA 8K V2 – production of the award body and logotype
• CNC machining of acrylic – production of clear and coloured plates

Materials

• Forward AM Ultracur3D ST 45 Resin – 3D printing of the award body and logo (a material choice ensuring precision and a high-quality surface)
• Clear acrylic – decorative plates imitating glass

Structural Design and Optimisation

The award body is designed in an inclined position, which enhances its visual dynamism but also places greater demands on the mechanical stability of the entire structure. During implementation, it was found that the weight of the milled acrylic plates exceeded the load-bearing capacity of the originally designed lower support section, making further structural optimisation necessary.

For production of the award body, SLA 3D printing on the Phrozen MEGA 8K V2 printer was selected, which, thanks to its large build area, allows a large part to be printed in one piece without the need for print supports. This approach was crucial not only in terms of surface quality, but also in terms of structural precision, as eliminating supports made it possible to retain clean surfaces without support marks and simplified subsequent post-processing.

The 3D printing material used was Forward AM Ultracur3D ST 45, a tough urethane photopolymer intended for SLA technologies. The material was selected for its mechanical strength, toughness and dimensional accuracy, which are crucial when producing larger parts with integrated structural features. These properties made it possible to design an internal pocket for a steel weight weighing approximately 300 g, shaped precisely to match the geometry of the printed body. 

The weight is secured using four screws, is completely concealed within the structure and covered by the lower acrylic plate, so it does not detract from the award's external design. Thanks to this modification, the finished trophy has a total weight of almost 1 kg, which contributes significantly to its solid and premium character.

The entire structure was designed as a standardised base, optimised for series production while maintaining consistent quality. It also allows rapid personalisation of individual pieces by replacing the dedication plate, without the need to alter the basic structure or manufacturing process.

Benefits and Added Value of the cotu^® Solution

The solution designed by cotu^® delivered a technically stable product with a carefully engineered structure, which retains its strength and balance even with the unconventional geometry of the award body. Thanks to the combination of SLA 3D printing and precise post-processing, high surface quality was achieved, meeting the requirements for prestigious and premium items.

The standardised design enables efficient small-batch production with consistent quality across individual pieces, while also offering rapid personalisation without the need to alter the basic structure. Another significant added value is complete project delivery, from preparing the 3D data to final assembly, giving the client a single technical partner throughout implementation.

Project Summary

The project for UGO! Media and Škoda Auto demonstrates that SLA 3D printing combined with conventional manufacturing technologies is a suitable solution not only for prototypes, but also for prestigious finished products, where the emphasis is on detail, stability and visual quality.

Thanks to its technical know-how and experience in small-batch production, cotu^® was able to deliver a solution that meets the high demands of a global brand while remaining efficient in terms of both production and future repeatability.

Are you looking for a technical partner for custom or small-batch production where precision, stability and surface quality are decisive? Get in touch with us and we will discuss the possible solutions for your specific project.