[3D Printing Applications] Success Story of Ultimaker Clients: 3D Printing of Sustainable Lighting Installations
Ultimaker is a leading global brand of 3D printers , having obtained two ISO international certifications in 2018. Its ease of use and stability are widely recognized by users. It provides complete 3D printing system planning, such as Cura slicing software and built-in filament settings, cloud platforms and interconnected monitoring systems, etc., which can make it very convenient for enterprises to manufacture high-strength, functional prototypes and quickly proofread within the enterprise.
The following is a case study of one of the brand's clients:
Urban Scale Interventions (USI) is a design studio dedicated to providing human-centered innovation for private and public organizations.
When commissioned to transform seven forgotten sites in Belfast, Northern Ireland, the USI team turned to 3D printing, drawing inspiration from local history to create a lighting experience. Their largest and most award-winning installation, "The Cellar Entrance," transformed the space outside Whites, the city's oldest pub. Once a hub of antisocial behavior, it is now a tourist hotspot and one of the city's most photographed locations.
To launch the project, the USI team brought the community together to inform every decision. In a series of public workshops, they surveyed over 1,500 residents to answer one question:
The answer reveals four collaborative design principles—creating experiences that are sustainable, fun, interactive, and safe .
Their (now award-winning) installation, using Ultimaker for 3D printing , will create a focal point, illuminating one of the hidden gems in Belfast’s rich commercial history.
Human-centered design
USI co-founder Ralf Alwani chose to explore FFF 3D printing after the outbreak of the pandemic. This technology enabled his team to control all aspects of the design and production process internally.
"It provides opportunities for people like us who are not advanced manufacturing experts to get involved in the design-to-manufacturing process."
The team quickly recognized other benefits. With the ability to visualize the entire installation in 3D using CAD, they were able to flexibly test sculptural ideas and then easily translate those designs into 3D prints. Compared to traditional model making, this production process was not only faster but also effectively eliminated human error .
Art Director Greg Edwards explained, “For us, this is a completely new organic design process. We are able to truly take these items from the design table to the street.”
But what exactly are these objects?
Ocean of floating spheres
After testing different designs, the team ultimately decided on the evocative "ocean sphere" design. This is related to Belfast's marine heritage and the area's history as a fish market.
The team quickly created iterations on-site, allowing them to explore more design options. Alwani explained:
“We can constantly replace parts, adjust them, and use them in ways that improve our designs. The ability to experiment throughout the manufacturing process completely changes the product output.”
There are 43 spheres in total, in 3 sizes. Since even the smallest size is too large for the 3D printer's build volume of 330 x 240 x 300 mm, the spheres are 3D printed in segments. The smaller size has 3 segments, and the larger size has up to 15 segments. In total, approximately 450 segments must be accurately 3D printed within a tight deadline.
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Despite the COVID-19 pandemic, the deadline
The main machines chosen to meet this enormous challenge? Three Ultimaker S5 3D printers .
"Having Ultimakers working behind the scenes is almost like having an extra pair of hands . It allows us to move other aspects of the project forward," said project architect Lorna McCarten.
These spheres are 3D printed using transparent PETG made from recycled plastic, with up to 15 parts per section.
Manufacturing resilience is crucial when a new wave of COVID-19 restrictions could cause project delays. The team has been working in an old flax mill in downtown Belfast, but Ultimakers' compact, modular nature means production can continue, Alwani says:
"Being able to install the Ultimaker S5 anywhere is really convenient. When lockdowns came, we were able to move them to an empty room in our house because of their small size, and we could continue manufacturing there before the deadline."
Graphic designer Rosanna O'Kane stated, "3D printing enabled our team to be hands-on with every step of the process, from design to manufacturing to installation. As a result, we understood everything about the project and were able to solve problems much more easily."
Simple, sustainable materials
In addition to reducing environmental impact through local manufacturing, USI further pursues the principle of sustainability .
They chose to use Filamentive's translucent PETG 3D-printed spheres (click the print settings to find them on the Ultimaker Marketplace ). This filament is wound onto a cardboard spool and is 89% made from recycled materials—plastic waste that would otherwise end up in landfills. For every kilogram of material sold, Filamentive also plants a tree to offset at least one kilogram of carbon dioxide.
Using only a single semi-transparent material means that the bulbs inside each sphere can dynamically change color to harmonize with the soundscape specifically designed for the installation.
The overall effect creates a new sense of place and an instant "Instagrammable" experience that visitors can share!
Urban-scale intervention won a placemaking award for its wine cellar entrance installation.
A Brighter Future for Belfast
And the timing couldn't be better! The installation not only transforms the site into a destination for people to explore and enjoy, but it also gives back to the hospitality industry—one of the sectors hardest hit by the COVID-19 pandemic.
As USI's work raises awareness of the possibilities of additive manufacturing, Alwani sees a positive future for the city's creative community:
3D printing offers a new and convenient way to bring manufacturing back into the hearts of Belfast’s young people who are eager to design and reimagine the future.
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