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Revolutionizing Rain Water Collection Solutions

CASE STUDY

Reducing Costs and Enhancing Fit for Lone Star Gutters with Custom 3D Printing Solutions

OVERVIEW

In this case study, we examine how Vedem Manufacturing provided a cost-effective and superior solution for Lone Star Gutters, a leading gutter company, by producing a custom rainwater collection overflow 90° elbow using advanced additive manufacturing, also known as 3D printing. Our solution not only saved the client significant costs but also resolved compatibility issues with local drainage systems.

CHALLENGES

High Costs: The elbows, sourced from an Australian company, cost $58 each.
Annual Requirement: Lone Star Gutters needed around 30 units per year, leading to substantial recurring expenses.
Incompatibility Issues: The product had metric measurements, making it difficult to fit with the standard drainage-rated pipes commonly used in Texas.
Complex Assembly: The 90° elbow required a gasket and wire mesh, which could not be purchased separately, adding to the complexity and installation time.

Our Approach

targeted approach using advanced additive manufacturing

Custom Design: We designed a rainwater collection overflow elbow that met Lone Star Gutters’ specifications and was compatible with standard drainage pipes
Integrated Solution: Our 3D printed design integrated the mesh into the elbow itself, reducing the number of parts and simplifying the installation process.
Superior Gasket: We 3D printed a gasket out of TPU (Thermoplastic Polyurethane) that was superior to the original, offering better performance and allowing for quicker replacements.
Cost-Effective Production: By leveraging 3D printing, we were able to produce each unit for only $8, significantly reducing the overall cost.
American Manufacturing: By manufacturing the product in Oklahoma using 3D printing, we ensured precise fit and timely availability, eliminating the issues related to metric measurements and long shipping times.

The implementation of our custom 3D printing solution yielded outstanding results

RESULTS

Significant Cost Savings: Lone Star Gutters reduced their cost per unit from $58 to $8, saving over $1,500 annually.
Enhanced Compatibility: The new design fit perfectly with the local standard drainage-rated pipes, improving installation efficiency and system performance.
Simplified Assembly: The integrated wire mesh reduced the number of parts and installation time, streamlining the installation process.
Superior Product: The American manufactured elbows, produced through advanced additive manufacturing, were of higher quality, offering better durability and performance compared to the imported product.
Improved Gasket Performance: The TPU gaskets were superior in performance, easier to replace, and enhanced the overall reliability of the system.

By partnering with Vedem Manufacturing, Lone Star Gutters successfully addressed their cost and compatibility challenges

CONCLUSION

Our custom 3D printing approach not only provided significant cost savings but also resulted in a superior product that met local specifications. The integration of the mesh and the superior TPU gasket further streamlined the installation process and improved system reliability. This case study highlights how Vedem Manufacturing’s advanced additive manufacturing solutions can drive significant improvements and cost efficiencies in specialized manufacturing needs.

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