Customer: Walkinshaw Group
Industry: Automotive Manufacturing
Technology: Stratasys FDM Technology (Fortus 450mc)
Application: Vehicle Remanufacturing, Prototyping, Jigs & Fixtures

Overview

With over 35 years of expertise in automotive innovation, Walkinshaw Group has transformed its business from high-performance vehicle manufacturing into one of Australia’s largest vehicle remanufacturing operations. As demand for right-hand drive vehicle conversions surges, Walkinshaw has expanded its capabilities and production speed—powered by Stratasys FDM additive manufacturing solutions, delivered and supported by Objective3D.

Challenge

Following the end of local vehicle manufacturing by major OEMs like GM in 2017, Walkinshaw needed to adapt. The company began focusing on large-scale vehicle remanufacturing, converting American-built left-hand drive vehicles—such as the RAM 1500, Chevrolet Silverado, and Toyota Tundra—into right-hand drive for the Australian market.

This complex process involved redesigning and rebuilding key vehicle components and required a fast, flexible solution for prototyping, fitment testing, and tooling without compromising precision or strength.

Solution

Walkinshaw partnered with Objective3D to integrate industrial-grade Stratasys Fortus 450mc 3D printers into their workflow, replacing earlier Stratasys systems. These printers became central to their Smart Manufacturing Hub, enabling fast and accurate prototyping and production of custom jigs, fixtures, and low-volume parts.

Walkinshaw’s engineers now use 3D printing during feasibility studies and trial fitments to validate assembly and design concepts. Objective3D plays a pivotal role, providing support with materials, maintenance, and troubleshooting, helping Walkinshaw engineers produce high-performance prototypes with exceptional turnaround times.

Results

• 10,000+ vehicles remanufactured annually, with 3D printing integral to the conversion process
• Rapid part iteration with trial-fit components printed and refined in real time
• Reduced production downtime and increased efficiency in prototyping and tooling
• High-performance materials like ULTEM™ allow fixtures to withstand extreme temperatures and vibration
• Creation of a dedicated Smart Manufacturing Hub integrating Fortus 450mc for continuous production support

Walkinshaw’s ability to design, test, and implement new components quickly has been a game-changer. The Fortus 450mc, with its broad material compatibility and high precision, now underpins their commitment to quality and innovation.

Quote

“We’ve been working with Objective3D for close to a decade. They’re more than a supplier—they’re a trusted partner. Their support and the reliability of Stratasys technology has become a vital part of our engineering process.”
— Phil Georgiou, CAD Manager, Walkinshaw Group

Technology Used

Stratasys Fortus 450mc

Materials: ULTEM™, carbon-fibre filled and flame-retardant filaments

Objective3D Services: System integration, technical support, material supply

Conclusion

By integrating Stratasys additive manufacturing into their remanufacturing operations, Walkinshaw Group has set a new benchmark in vehicle conversion quality and speed. Their long-standing partnership with Objective3D ensures continuous innovation and production agility, reaffirming their place at the forefront of automotive engineering in Australia.