1,200 × 1,000 × 700 mm
Overall dimensions
53
Printed sections
3 weeks
Start-to-delivery turnaround
PLA + PETG
FDM materials
The Challenge
3D ForgeHub manufactured a large-scale motorcycle trailer plug for a customer preparing for mold production. At approximately 1,200 × 1,000 × 700 mm, the plug's size and geometry made it impractical to produce as one printed component. It far exceeds the build volume of a single FDM printer.
The project required a sectioned manufacturing approach: individual components printed separately, then accurately assembled and finished as one unified structure, all within a three-week delivery window.
The assembled fender plug, front elevation, with wheel arch and section joints visible.
53 → 1
Fifty-three individually printed sections, joined into one continuous plug. Sectioning turned an impossible single print into a controlled, repeatable build. This is how 3D ForgeHub approaches large-format 3D printing in Waterloo.
Our Solution
PLA and PETG FDM printing, assembly, and a primer finish. Follow the actual project build below.
Sub-assemblies staged before final joining.
Stage 01
The overall geometry was divided into 53 printable sections, each sized to fit the build volume, with the joints planned so the assembled plug would read as one continuous form.
53 sections planned
Printed sections joined, with seams visible close up.
Stage 02
The individual components were manufactured using a combination of PLA and PETG FDM 3D printing, with 53 sections in total, printed and staged for assembly.
PLA + PETG · FDM
The fender sections joined into a single structure.
Stage 03
The 53 printed sections were joined and integrated into one complete structure, with the fender sections shown assembled ahead of surface preparation.
One unified structure
The trailer tub after primer, showing the interior and wheel arches.
Stage 04
With assembly complete, a primer coating was applied across the full structure, including the tub and lid, to prepare the assembled plug for subsequent mold-making work.
Primer-coated
The finished lid, primer-coated and ready to hand over.
Stage 05
The assembled, primer-coated plug was completed and delivered within three weeks. A 1.2-metre tooling component, primer-coated and prepared for mold-making, produced without a single oversized print.
Delivered · 3 weeks
Up Close
These details show the printed sections and their joints as assembled, before primer was applied.
End section, showing the joint line and wall finish.
End panel meeting the wheel-arch section.
Side wall, showing the printed surface and seam detail.
Project Results
Overall size
Approx. 1,200 × 1,000 × 700 mm
Total sections
53 printed sections
Technology
FDM 3D printing
Materials
PLA and PETG
Finishing
Fully assembled and primer-coated
Turnaround
3 weeks
End use
Plug for mold-making preparation
Large-format, sectioned 3D printing provides a practical way to produce custom tooling geometries without manufacturing the entire structure as a single piece. By combining printed sections with assembly and surface finishing, 3D ForgeHub helped turn a large digital design into a physical tooling component ready for the next stage of manufacturing.
The result was delivered primer-coated and prepared for mold-making, providing the starting point for the customer's mold production.
The primer-coated lid, with the plug prepared for mold-making.
Start a Project
From functional prototypes and production aids to large, multi-section tooling components, 3D ForgeHub supports engineering and manufacturing teams with application-focused additive manufacturing. If it doesn't fit in one build volume, we'll section it, print it, and finish it, like this plug.
3D Printing · Waterloo, Ontario · 3dforgehub.com
At 3D ForgeHub, innovation and precision come together to deliver professional 3D printing and additive manufacturing services in Waterloo.
With more than a decade of experience in manufacturing, engineering, and advanced 3D design, our team specializes in producing high-quality custom 3D printed parts, rapid prototypes, and small-batch manufacturing solutions for businesses and individuals across Canada.
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