AMC Case Studies

Case Studies 

Reverse Engineering, Structured Light Scanning, 3D Printing
Troy Industries
Challenge: Reverse engineering of parts with complex geometry using structured light scanning and the Markforged 3D Printer.

CCAT was tasked with assisting Troy Industries by using reverse engineering to generate a 3D model of selected trigger pack and buttstock product parts with very complex geometries. The parts were scanned using structured light scanning and a physical model was then generated using the Markforged 3D printer. Troy Industries then took the model and attached it to the assembly of a retro-fit kit to successfully check the fit and function of the scanned part before manufacturing its mating parts in the final assembly. Troy Industries was able to save money as well as manpower by using reverse engineering and 3D printing model parts. Guess and check errors were eliminated and product quality was dramatically improved. By accelerating the process toward production, Troy Industries gained the opportunity to hit the market quicker and generate a higher sales volume with their new retro-fit kit.


Precision Machining
Customer: Flanagan Industries

Challenge: Reducing machining cycle time

The CCAT team, comprised of engineers with expertise in machining, tooling, and optimization software, was able to significantly reduce the cycle time of certain roughing and finishing processes on an aerospace part for Flanagan Industries. The team optimized toolpath parameter settings, toolpath patterns, and the selection of cutting tools to increase machining efficiency. CCAT significantly reduced the machining cycle time for two operations – one by 35.1 percent and the second by 47.7 percent. The optimized processes for both operations were implemented by the company.


Additive Metal Manufacturing
Customer: University of Hartford School of Engineering
Challenge: Property differences between deposition rates

CCAT’s additive manufacturing team was tasked by the University of Hartford, College of Engineering, Technology, and Architecture with exploring material property differences between deposition rates of 300W laser power and 2000W laser power. normal and high deposition rates. For this project, we completed two builds and analyzed basic material characterization including ultimate strength, elongation, modulus of elasticity, and microstructure analysis. The build time statistical regression model for the additive directed energy deposition process (LENS) was also developed.


3D Plastic Printing
Customer: Connecticut Children’s Medical Center
Challenge: Mixing different material plastics and polymers

CCAT worked with the Connecticut Children’s Medical Center to advance techniques for complex child trachea surgery. The trachea has bone, muscles, and tendons of varying strength and density. To replicate the trachea, we used a 3D printer capable of producing flexible and rigid materials by fusing together polymers, elastomers, polycarbonates and ABS-like resins simultaneously. The result was a remarkably realistic child’s trachea.






Produced two excellent parts for us, using the ProJet 5500X which is a unique capability only accessible thanks to CCAT. The fact that CCAT can work with student SolidWorks files which are not always the highest quality is greatly appreciated.

Allan Penda, Adjunct Professor, Department of Mechanical Engineering, University of Hartford June 14, 2016

CCAT made it possible to translate a complex part design with detailed features into a complete and toleranced part design drawing. CCAT then developed the multi-pass and multi-sided manufacturing process, and machined the part within tolerance. I found the people at CCAT to be knowledgeable, professional, and easy to work with. The CCAT AMC team took a preliminary idea from a starting CAD file to a fully documented project and delivered a fabricated part that works. A really great job."

Michael Goldstein, Ph.D., Rx Analytic, Inc. August 25, 2016

Not only do they have access to the latest technology and manufacturing processes but also have the technical staff to help figure out what it is you actually need.

Erik Herold, Lead Mechanical Engineer, Dynamo Micropower June 14, 2016

The Technical Assessment CCAT conducted was an eye-opener and stimulated some really good discussion with my staff.

Tyler Burke, President, Turbine Technologies February 4, 2016

The Technical Assessment process CCAT conducted has allowed our organization to clearly identify the key points that will allow us to run more lean and efficient by highlighting improvement areas in our process.

Michael C. Malota, CFO, Windmade Products, LLC February 4, 2016

As a company known for innovation in the development of advanced manufacturing systems, we recognize CCAT's research and manufacturing technology expertise.

Richard Grylls, Ph.D., LENS General Manager, Optomec February 4, 2016

The Technical Assessment highlighted opportunities for improvement that will help my company be more competitive and grow.

Anonymous Customer Survey February 4, 2016