Every stage of your product,

developed under one roof.

With our in-house designers, engineers, and machinists working together from day one, issues get fixed in CAD - not discovered in production, so you get your product shipped without compromising your vision, or timeline.

De‑Risk Product Development Before Tooling

We are a design‑first additive manufacturing partner specializing in high‑performance thermoset plastics, supporting R&D teams, startups and manufacturers from initial concepts through first article and small production runs. We help de‑risk additive tooling and part development by prototyping with the final materials.

Our secret weapon – Carbon DLS™.

Benefits of Carbon
Additive Manufacturing

The Carbon DLS™ process lets you produce engineering-grade parts with predictable mechanical responses in both rigid and elastomeric resins. Prototype early and often, reducing product development cycles to get to market faster. Plus, create variable density and performance out of a single material.

Get ready to leverage the power of our cutting-edge Carbon printing and design services.
Engineer and 3D Technician review prototype_EDIT-1-1
Sherpa Element 3

Industries & Applications ideal for Carbon DLS™

Robotics

End Effectors, Grippers, Robot Skins, Footpads, and Protective Interfaces

Industrial and Automation

Jigs, fixtures, enclosures, damping components, end effectors and grippers

Specialty Automotive Components

Clips, housings, functional brackets, connectors, custom parts Medical and diagnostic device components Device housings, diagnostic components, therapeutic products

Semiconductor & electronics

Jigs, fixtures, enclosures, damping components, soldering fixtures, manifolds, cable management, PCB test fixtures

Consumer products

Wearables, Sporting goods, Saddles, Helmet liners, Gloves, Insoles, Footwear, Backpacks, Workwear, Padding Grips, Car Seats. We have worked in most the industries and applications listed.

We have worked in most the industries and applications listed.

How it works?

The Carbon DLS™ printing process is enabled by a thin, oxygen-permeable window and dual-cure materials. The use of dual-cure materials with a second heat-activated chemistry ensures that printed parts overcome the weaknesses and brittleness commonly associated with traditional resin-based 3D printing. This results in robust mechanical properties comparable to traditional manufacturing plastics, including injection molded parts.

 

Sherpa Element 3

Why Sherpa (Not an Upload and Print Vendor)?

Many teams have tried Carbon DLS through upload‑and‑print vendors—and walked away disappointed.

The difference is our design focused approach.

We are not here for the mass production of finished parts. As a Carbon partner, we are one of the few focused guiding you from prototyping to scaled production.

Sherpa brings:

grey bullet  End‑to‑end product development experience

grey bullet  Deep DfAM expertise for Carbon platforms

grey bullet In‑house printing tightly coupled to design

grey bullet  Honest guidance on process selection

Carbon 3D Printing and Product Design

 

Carbon DLS is a strong fit when:


SHE - Testing & Validation (2)-1 Mechanical performance must be validated early

SHE - Testing & Validation (2)-1 Iteration speed matters more than unit cost

SHE - Testing & Validation (2)-1 Tooling risk is high or premature

 

It may not be right when: 


SHE - Testing & Validation (2)-1 Extremely high volumes
are imminent

SHE - Testing & Validation (2)-1 Tight cosmetic tolerances demand steel tooling

SHE - Testing & Validation (2)-1 A simpler process meets the need

When Carbon DLS Is (and Isn’t) the Right Choice

We’ll help you decide because the wrong process costs more than the right one.

QC 3D printed parts-1-1

three-circles

What We Do

We help produce parts quickly with multiple design iterations. This lets you focus on validating form factors, ergonomics, and electronics integration.

Our team can start with anything from a napkin sketch to fully developed CAD. We can optimize your design for Carbon printers by minimizing support material, reducing hand finishing time, developing custom surface textures, and applying lattice structures.

 

Let’s Talk About Your Program.