Additive Manufacturing 3D Printing


Product Design

Nexus3 has experience designing products for the aerospace and consumer industries.  We follow a five phase design approach that includes checklists and design reviews to ensure that nothing is missed.  

Phase 1 - Kickoff

During this phase, we confirm contract requirements with the client including technical, schedule, and commercial requirements.  This phase is quick and typically occurs within a week after the project is awarded.  This phase is critical for setting the project requirements and ensuring that there is agreement on the project deliverables.

Phase 2 - Preliminary Design

Preliminary design work is performed during this phase.  Activities may include:


  • Design Concept Selection

  • 3D Modeling

  • Preliminary Design Analyses

  • 3D Printed Prototypes

Phase 3 - Critical Design

Detailed design work is completed in this phase.  At the end of this phase, a design will be ready for testing and qualification.  Some of the activities performed in this phase may include:

  • 3D Models

  • 2D Drawings

  • Dimensioning and Tolerancing

  • Final Design Analyses

  • Test Plans

  • Manufacturing Plans

Phase 4 - Qualification

Any testing required for product qualification is performed during this phase.  This may include customer and regulatory testing requirements.

Phase 5 - Production Transition

This is the final phase of the design process.  Testing results and manufacturing documentation is reviewed to ensure the product is ready for low-rate initial production.

To learn more about our services or to request a quote, click the button below or call us today at (623) 248-7722.

Quality 3D CAD Models

If you have an idea, we can model it.  Prototypes, fixtures, tooling, or low volume production.  Just let us know what you need.  We have professional experience designing models for both traditional manufacturing and 3D printing.  Contact us with your design challenge!

  • Solid Models

  • Assemblies

  • 2D Drawings

  • Fits and Clearances

  • Geometric Tolerancing

To learn more about our services or to request a quote, click the button below or call us today at (623) 248-7722.

Designing Products for 3D Printing Using DfAM

At Nexus3, we understand the strengths and weaknesses of each AM process and can help you select the correct technology for your application.  We follow a structured plan that encourages brainstorming and ensures creative solutions for your projects.  The plan produces rapid results and is designed to avoid “over the wall” designs where manufacturing feedback is received late in the design process.


Here is how it works.

Step 1 – We clearly define the product application and requirements.


Step 2 – We brainstorm design and manufacturing ideas that will fulfill the product requirements.

  • Is this project a good candidate for Additive Manufacturing?

  • What is the objective of the design?

  • What materials will be used?

  • Which AM process is best suited for this project?

  • Are there any industry regulations to consider?


Step 3 – We generate the solution(s), prototype the products, evaluate the results, and repeat until a final solution is reached.


Using this process allows us to rapidly converge on a final solution for your project.  Feedback is quickly incorporated, and more prototypes are evaluated in a shorter period of time.


Contact us if you are considering Additive Manufacturing technology for your next product, or if you are in the process of redesigning an existing product.  We can help you evaluate performance and cost benefits such as consolidation of parts, complex geometries, weight reduction, and customization.

To learn more about our services or to request a quote, click the button below or call us today at (623) 248-7722.