Turning a Side Hustle into Success

ZapWizard, founded by Josh Driggs in Texas, shows how a compact operation can yield impressive outcomes. By dedicating just three hours each night, Josh operates his business creating accessories for Leatherman tools—like holsters and tool attachments—using Formlabs’ Fuse 1 for selective laser sintering (SLS). In under seven months, a personal investment of $135,000 covered the cost of the printer and materials, and the company shipped around 3,600 units—achieving full ROI.

From Outsourced to In-House Production

Prior to investing in his SLS setup, Josh relied on Shapeways to print and ship parts. Each $45 holster earned roughly $5 in profit—a model that worked, until Shapeways raised prices and eventually shut down. Faced with inflated costs, delayed timelines, and inconsistent finish quality from other vendors, Josh chose to internalise the production.

Consistent, High-Quality Results

After sourcing his top designs to multiple U.S. and overseas vendors, Josh found the quality inconsistent. Issues with tolerances, colouration, and finishes persisted. In contrast, the Fuse 1 delivered the precision and consistency he needed—enabling control over print orientation, colouring, and quality—all vital for meeting customer expectations.

“I utilise SLS 3D printing to its fullest potential. The Fuse 1 really did save my business.”
— Josh Driggs, Owner, ZapWizard

Fast Onboarding and Print Timelines

Josh’s Fuse 1 began printing parts in-house by September 20th, shortly after Shapeways ceased operations on July 2nd. With SLS capabilities under his roof, he regained production speed and control.

Lean Operation, Big Returns

Operating solo during nights only, Josh managed print prep, production, and shipping. Despite the condensed workflow, the operation proved efficient, with hundreds of parts printed weekly and high-quality outcomes achieved at minimal overhead. The low-volume, side-by-side production model enabled rapid scale-up without added personnel.

Why SLS Made Sense for ZapWizard

• No minimum orders or mold costs—ideal for small-batch production.
• Complete control over print settings, material consistency, and finishing.
• Ability to maintain quality standards overnight.
• Strong community demand for custom Leatherman accessories.

Key Takeaways for Small Businesses

ZapWizard’s journey illustrates how small-scale SLS printing can be a game-changer:

• A single printer, operated part-time, can pay for itself in a matter of months.
• Internal printing enables tight quality control and fast iteration.
• Side-hustles can scale quickly with smart, targeted investments.

Conclusion

By choosing the Fuse 1 and mastering his workflow, Josh transformed a casual hobby into a profitable business, shipping thousands of parts and achieving full ROI within seven months. His story highlights the power of accessible desktop SLS to unlock growth for small-scale entrepreneurs seeking precision, efficiency, and autonomy.

Objective3D is proud to bring the power of Formlabs’ SLS technology—like the Fuse 1—to entrepreneurs and small businesses across Australia and New Zealand. As an official Formlabs partner, Objective3D provides the tools, training, and support needed to help you turn passion projects into profitable ventures. Whether you’re just starting out or scaling up, we’re here to help you harness the full potential of 3D printing with confidence.