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Case Studies
Real Customers. Real Results.

Fathom customers love our hands-on approach to engineering and production. We work closely with them to refine and optimize part designs and move them into production quickly. This personalized approach is reflected in these case studies, which explore the value we’ve created for the customers profiled in them.


Technologies Used //

  • MJF
  • FDM
  • PolyJet
  • Injection Molding

Fathom accelerated product development using additive technologies and then provided rapid injection mold tooling for field trials of this innovative product, which is being used to help treat Opioid Use Disorder.


Technologies Used //

  • STEP

Because thermoplastic parts could be made without tooling, Fathom saved this customer a significant amount of time and money on a custom scoreboard project.

VSi Parylene

Technologies Used //

  • Sheet Metal Fabrication

Fathom helped solve some manufacturability issues with the elegant, modern sheet metal skin of this machine and helped this customer reduce its product development time by 50%.

Guillermo de Toro’s Pinocchio

Technologies Used //

  • PolyJet

Director Guillermo del Toro’s use of stop animation for his movie, Pinocchio, required strict continuity for the mechanically-operated puppets, especially for the shapes and colors of Pinocchio’s nose, head and eyes. Fathom produced thousands of variations of these components using PolyJet and developed a workflow and quality-control process to meet the moviemaker’s unique needs.

Conformal Cooling

Technologies Used //

  • DMLS

A customer was having problems with plastic closures warping as they cooled because the tool contained a deep draw cavity. Fathom designed a core insert made using DMLS that contained conformal cooling channels. They drew heat away from the closures, enabling them to cool faster without warping.

DePuy Synthes

Technologies Used //

  • CNC Machining
  • Swiss Turning

Fathom was asked to provide design input on a second-generation RIA, for which it provided a stainless steel drill head and nitinol drive shaft. The team recommended design changes that improved its manufacturability, reduce the number of parts and help reduce its cost.

Across National
Time Zones

Precision manufacturing
from coast to coast.

1050 Walnut Ridge Drive
Hartland, WI 53029

444 W. 21st St. Ste. 101
Tempe, AZ 85282

46758 Lakeview Blvd
Fremont, CA 94538

7770 Washington St.
Denver, CO 80229

14000 N.W. 58th Court
Miami Lakes, FL 33014

1207 Adams Drive
McHenry, IL 60051

1401 Brummel Ave
Elk Grove, IL 60007

13758 Johnson Street NE
Ham Lake, MN 55304

1920 Slaterville Rd.
Ithaca, NY 14850

401 W. Shore Blvd.
Newark, NY 14513

1513 Sam Bass Rd.
Round Rock, TX 78660

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