Welcome! Midwest Composite, Studio Fathom, GPI Prototype and Summit Tooling are now Fathom Learn more

Rapid Manufacturing Services

Comprehensive Prototyping Complex Manufacturing Automated Quotes Customer Responsiveness Speed to Completion

See Why Customers
Rely On Fathom

Fathom is the largest privately held digital manufacturing company in North America. We are accessible with a national manufacturing footprint and uniquely blend industrial 3D printing and additive technologies with traditional manufacturing.

Case Study //
Real Customers. Real Results.

A customer came to Fathom with a complex project that spanned the technologies and processes of rapid production—and needed it done fast. Fathom delivered.

20,000 Parts // Within 27 Days


55+ Tools to Injection
Mold 15,000 Parts

First Article in 2 weeks


3,000+ 3D
Printed Parts


2,000+ Metal
Fabricated Parts

Hybridized Services Used //

3D Printing / Additive Manufacturing—PolyJet, SLS, MJF.

DFM Analysis + CAD Mods.

CNC Machining. Laser Cutting.

Stamping. Die Cutting. Post-Opp Drilling.

24-hour Turnaround Urethane Casting.

Injection + Compression Molding.

Model Finishing. Insert Assembly.

Advanced Project Management.

Compare Fathom to Other Digital Manufacturers

We make your parts to your specifications we won’t put you in a box of manufacturing constraints, and we’re definitely not a broker who will send out your parts to other companies. We’re driven to provide a DIFFERENTIATED customer experience with speed, urgency and agility. Our comprehensive services stand out against our competitors.

Rapid Manufacturing Services Overview

Fathom built its production centers on an enterprise-level 3D printing and additive manufacturing expertise first, then integrated traditional manufacturing equipment and processes second. Not to be confused with a service bureau or machine shop, Fathom has built an advanced manufacturing facility that specializes in all aspects of production realization from mechanical concept development to prototyping to the fabrication of low- to high-volume production parts. This unmatched expertise allows Fathom customers to drive greater innovation at an industry-leading pace without compromising design intent.

Fathom is headquartered in Hartland, Wisconsin with services offered nationwide. Additional offices and production centers are located in Seattle (WA), Oakland (CA) and Holland (OH).

Fathom serves companies of all sizes across many industry types such as medical, consumer products, electronics, automotive, aerospace and sporting goods. Fathom experts work with a wide range of professionals at companies involved in the product development of hard goods—designers, engineers and creative professionals alike who need to test products faster, verify designs earlier and elevate their entire product development and production processes.

Fathom takes a multi-disciplinary approach because advanced technologies and traditional methods are complementary. While Fathom commonly uses additive technologies to solve highly complex problems, the result is significant when those differing strengths and weaknesses of advanced and traditional methods are used to augment each other. By working with Fathom, you can expect the highest quality of service, resourcefulness and ability to support you throughout product development and into production.

Fathom offers specialized managed equipment solutions that augment a company’s in-house digital fabrication operations. This comprehensive and customizable staffing approach accelerates implementation, streamlines workflow and decreases downtime. By leveraging on-site managed services with Fathom, organizations fully realize the benefits of equipment ownership without having to dedicate internal resources to hands-on operations. Additional support options are available—each managed service plan is customized to fit the unique production needs of a company for the best results.

What is Rapid Manufacturing?

Rapid manufacturing is the use of software automation which directs equipment to rapid manufacture a product. It is the low-volume and on-demand production of parts. In addition to injection molding, 3D printing, CNC machining and other manufacturing processes may be used.

How Can Rapid Manufacturing Benefit Your Business?

Rapid manufacturing has many benefits including //

  • Produce Quality Plastic & Metal Parts in Days
  • Save Money
  • Receive Design Feedback Quickly
  • Test Design
  • Reduce Production Issues
  • Reduce Product Development Cycles
  • Reduce Technical & Supply Chain Risk
  • Reduce Total Cost of Inventory & Development

Rapid Manufacturing Services by Fathom Include //

  • Fused Deposition Modeling (FDM)  //This technology is an ideal fabrication method for all kinds of applications because of its wide range of engineering-grade thermoplastics—from concept models, functional prototypes and end-use parts such as final goods and manufacturing aides (e.g., jigs and fixtures).
  • PolyJet (PJ) //This technology can achieve smooth surfaces, thin walls, and complex geometries with accuracy as high as 0.1 mm—the one and only technology that supports a wide selection of materials with properties that range from rubber to rigid and transparent to opaque. It is commonly used for prototyping but additional uses include jigs and fixtures.
  • Stereolithography (SLA) //This technology is ideal for high-resolution finishes regarding medium- to large-sized parts. While there are less materials to choose from versus PolyJet, it is an extremely cost-effective solution for creating durable, aesthetically pleasing parts of considerable size on a tight deadline.
  • Multi Jet Fusion (MJF) //This technology is quickly becoming a popular choice for 3D printing prototypes and production parts. Ideal uses for MJF are enclosures, electronics housings, complex ducts, lattice structures, and functional assemblies. MJF is capable of 3D printing parts with high detail. It is especially suitable for applications that require durability (e.g., snap fits).
  • Selective Laser Sintering (SLS)  //This technology is commonly used to create models, prototypes, and end-use parts in durable, engineering-grade thermoplastics. Especially great for larger quantities of parts. Consider SLS for applications that involve high-complexity and organic geometries, as well as parts requiring durability and flexibility.
  • Direct Metal Laser Sintering (DMLS) //Metal 3D printing, also known as direct metal laser sintering (DMLS) and direct metal laser melting (DMLM) is an additive layer technology. A metal 3D printer utilizes a laser beam to melt 20-60 micron layers of metal powder on top of each other. Powdered metal is spread across the entire build platform and selectively melted to previous layers. This additive process allows metal parts to be grown out of a bed of powdered metal. The process is like other polymer-based 3D printers that use powder bed fusion.
  • Metal 3D Printing //Metal 3D printing, also known as Direct Metal Laser Sintering (DMLS) and Direct Metal Laser Melting (DMLM) is an additive layer technology. A metal 3D printer utilizes a laser beam to melt 20-60 micron layers of metal powder on top of each other.
  • CNC Machining //Computer Numerical Control (CNC) machining is a manufacturing process during which a pre-programmed computer software directs the movement of factory machinery and tools. CNC machining can control a variety of complex machinery, from mills and routers to grinders and lathes. Using CNC machining allows three-dimensional cutting tasks to be accomplished with a single set of prompts. This process has become popular because there is no need for a live operator to push levers, buttons or wheels. Once a CNC machine has been activated, the cuts are programmed into the software and then communicated to the tools and machinery which perform the task, similar to a robot. CNC machining is ideal for projects requiring production-grade materials and rapid prototyping of tight-tolerance plastic and metal parts with excellent surface finishes. The repeatability of the process also opens up the possibility of producing high-volume manufacturing of parts using CNC machining.
  • Urethane Casting //Urethane casting is most commonly used during the prototyping process and can generally be expected to hold +/- .010″ tolerances with +/-0.003 in/in (whichever is greater). For urethane casting equipment and parts with tight tolerance requirements, Fathom generally recommends CNC machining or injection molding. Regarding soft parts, there is a Shore A tolerance of +/-10. Please note, the above tolerances are not guaranteed because geometries vary and every application is different, so please speak directly with one of Fathom’s urethane casting experts.
  • Tooling & Injection Molding //Fathom has formed The Fathom Tooling+ Team, building on more than eight decades of tooling and injection molding experience. Fathom offers a single-source global solution that supports any size company’s low- to high-volume molding needs. In-house experts working side-by-side are improving the injection mold business model—accelerating the quoting process, as well as including Design for Manufacturing (DFM) overview with every initial quote.
  • Model Assembly & Finishing  //Services include sanding, priming, painting and assembly. Fathom can also create stock components and custom artwork.
  • Engineering & Design //The Engineering & Design Team at Fathom is a group of experts with industry-leading additive manufacturing experience. These highly trained engineers and designers can be contracted to support your in-house design team throughout the product development process from prototyping to production. They help teams use additive technologies in conjunction with traditional manufacturing methods to drive greater innovations.
  • Managed Services //Fathom offers specialized managed equipment solutions that augment and accelerate a company’s in-house digital fabrication operations from additive to subtractive to formative manufacturing systems. This comprehensive and customizable staffing approach accelerates implementation, streamlines workflow and decreases downtime.

By leveraging on-site managed services by Fathom, organizations fully realize the benefits of equipment ownership without having to dedicate internal resources to hands-on operations. Equipment operation includes but not limited to FDM, PolyJet, SLS, SLA, MJF, Nano Dimension, metal-based additive, CNC machining, and laser cutting.

Designers and engineers have the opportunity to push the limits of how they design and manufacture products in very big ways.

Download a quick guide on all services offered Learn More.

Rapid Manufacturing Methodologies

Product Development Methodologies //

Fathom focuses on the need for total design freedom and faster speeds in our product development and manufacturing processes. Consumer products are getting smarter every day and users are more empowered by these innovations. Times are changing and product development demands are increasing quickly, but access to new technologies has never been easier and more cost-effective. Barriers in product development will continue to be broken down because advanced technologies and techniques continually change the ways products are designed and manufactured.

Front-Loaded Methodology //

Inspired by Stefan Thomke, Fathom encourages a “front-loaded process” during product development by engaging in many iteration cycles sooner versus later. Teams can increase knowledge and decrease assumptions earlier in the concept development process when it is less costly to make changes.

Question, Build, Test, Learn //

Building on Fathom’s encouragement to take a “front-loaded” approach, it is important to note that teams should question, build, test and learn throughout all phases of product development before going into production. Direct digital manufacturing is becoming increasingly more common because additive technologies allow for on-demand production (e.g., build the latest, most improved version of your design as needed).

Outside-In Methodology //

By focusing on how a product should function rather than how it’s made, companies can drive greater innovation and push the limits of manufacturing. Whether manufactured traditionally, additively or a hybrid of both, Fathom promotes an “outside-in” approach.

Increase Product Possibility //

By leveraging the outside in approach, we can focus on limiting blind spots (traditional manufacturing constraints) and maximizing product possibility. Fathom is driven to augment conventional manufacturing using advanced technologies and unique processes.

Core Capabilities 3D Printing & Additive Manufacturing, CNC Machining, Urethane Casting, Tooling & Injection Molding, Finishing & Assembly
Additive Technologies Fused Deposition Modeling (FDM), PolyJet (PJ), Stereolithography (SLA), Selective Laser Sintering (SLS), Multi Jet Fusion (MJF), Direct Metal Laser Sintering (DMLS)
Engineering & Design Fathom’s Team of Designers & Engineers Who Can Support a Company’s In-House Product Development Team Throughout Prototyping and Production Phases
Managed Services Fathom’s Part-Time & Full-Time Staffing Solutions That Enhance Your In-House Fabrication—Fathom Experts Operate Equipment, Manage Work Orders & Much More
Additional Services Training Programs Include Design for Additive Manufacturing (DFAM) + Traditional Manufacturing Processes (e.g. Injection Molding, CNC Machining & More)
+ Consultation, DFM/DFAM Guidance, Technology & Material Evaluation, Research & Development, etc.

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Comprehensive Capabilities for Rapid Manufacturing

At Fathom we offer a unique advantage of speed and agility-our experts help companies go from concept to prototype to manufacturing in ways not previously possible. 

90+ Machines  
SLS / / Two-day  SLA / / Next-day 
FDM / / Next-day DMLS / / Three-day 
PolyJet / / Same-day MJF / / Two-day

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30 Second Quotes
Prototype Tool / / As soon as 10 days
10K Parts / / 10 days
Production Tool / / As soon as 3 weeks

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3 & 5 Axis Milling & Turning
(Plastics, Composites and Metals)

Tolerance Accuracy Range
from +/-0.001″ to 0.005″

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Injection Molding Adjacent
without High Costs of Metal Tools

Most Commonly Used for High-Volume
Prototyping & Bridge to Production

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Finishing, Production Painting and Color Matching

Assembling, Including Embedded Electronic
Components, Threaded Inserts, and More

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CAD, DFAM and DFM Services

Apply Methods to Increase Speed
and Decrease Total Cost

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Highly Trained Staff / / Full-Time & Part-Time
Support as Short-Term & Long-Term Strategy

Decrease Downtime with Customizable
Staffing Accelerates Implementation

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Let’s get started.

Fathom is driven by advanced technologies and methods that enhance and accelerate today’s product development and production processes.