01 / Challenge
Challenge
A design brand wanted to launch a physical product without committing to injection mould tooling before they had sales data.
Small-Batch Production — 2026
Modular Desk System
A tessellating desk organiser family of nine parts that clip together in any arrangement, produced as a 200-unit retail run.
PLAFDMRetail
Preparing 3D view
Loading geometry and materials.
- Project
- Modular Desk System
- Material
- PLA
- Technology
- FDM
- Print Time
- 3 hours
- Layer Height
- 0.20 mm
- Weight
- 55 g
- Dimensions
- 90 x 90 x 60 mm
- Industry
- Retail
02 / Design
Design
Nine modules were built on one hexagonal grid pitch with a dovetail clip that prints without supports in any orientation.
03 / Printing Process
Printing Process
Printed twelve-up per plate in PLA at 0.2 mm to a fixed process sheet, with a first-article check at the start of every batch.
04 / Final Result
Final Result
Two hundred units shipped across six weeks with a 1.5 percent reject rate. The line sold through before tooling was ever quoted.
Gallery
Through the build
Four moments from the job, in the order they happened.
- 01
The nine modules - 02
Dovetail clip detail - 03
Twelve-up production plate - 04
Retail arrangement
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Modular Desk System
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