The Communications Review – Sepura R&D Team Improves Product Design and Prototyping with 3D Printing



In-house 3D printing improves product design and prototyping for Sepura’s research and development team.

Sepura customers depend on mission-critical devices to maintain communications throughout their operations. To ensure that devices scale effectively to meet these challenges, Sepura must work in an agile, flexible and innovative way. Using the right prototyping technology, such as 3D printing, now allows the company to perform early testing, verify meaning, and improve their level of customer engagement.

A good example is a recent battery box design. While the prototype would normally have taken two weeks to manufacture, using the in-house 3D printer, Sepura’s research and development (R&D) team was able to test the modified design within 24 hours. This allowed for faster and easier design iterations and accelerated development.

Since updating its 3D printer in November 2021, Sepura has seen significant improvements in this capability. Their new Stratasys J35 Pro printer has precise design and complex hardware capabilities that can accurately mirror final production parts.

Robert Wright is a Senior Mechanical Design Engineer at Sepura and works closely with the wider development team, using the 3D printer to speed products to market.

He said, “We already knew the benefits of 3D printing from having used Stratasys PolyJet technology in the past. The J35 Pro adds another important layer to our existing 3D printing capabilities – not only can we now cost-effectively create realistic prototype models in-house, but we’ve also reduced our production time significantly, which is a huge plus for the organization.”

Paul Tindall, Sepura R&D Manager; “The variety of materials available with the J35 Pro allows us to create accurate prototypes and means that our customers receive a detailed, tangible model they can hold, move and test. We have found the Elastico™ material particularly beneficial – we are able to produce prototype seals that simulate the look, feel and function of rubber and can withstand repeated bending and flexing.


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