the new, new in manufacturing: integrated workflow (nerd alert)

My favorite thing about this case is that it represents the absolute state of the art in modern design and manufacturing technology workflow. I use Autodesk Fusion 360 for all of our CAD design these days. I opened the 3D flashlight model and "built the box around the light," using the flashlight CAD data to drive the dimensions of the box. No need to take any physical measurements of the light in order to determine the geometry of the box.

The lid is a mirror image of the bottom, and I was able to automatically "mirror" the part so any design changes made to the bottom portion are automatically updated to the lid. Basically you can get two parts out of a single design, and not have to remember to update every change on both parts. Sounds small, but in reality is a huge win.

Here comes the good part. Normally I'd machine these components, but that requires hours of CAM programming to pick all of the cutting tools, set the tool paths, figure out how to hold the part inside the CNC, find all the cutting tools, buy some if I don't right ones, set those tools into tool holders, measure all of them after installation...and we haven't even cut any metal yet.

With 3D printing I can go straight from "art" in Fusion 360, to "part" on the 3D printer. Literally export the model as a 3D printer file, load that file into the printer program...and print the part. It did take about a dozen prints to get everything perfect (my fault, not the printer's) but the design/development process was significantly shorter (and a fraction of the cost) of doing it the "old" way. CNC is so 2020.