Accelerating Custom Part Production for Environmental Solutions: Apria Systems and UltiMaker S6

Apria Systems builds custom environmental engineering solutions for clients around the world. Every project needs parts designed from scratch. Before 3D printing manufacturing became part of their workflow, those parts came from CNC machining. It worked, but it was slow, costly, and limited in the shapes it could produce. Switching to the UltiMaker S6 changed how the company designs and delivers 3D printing custom parts for its clients.

About Apria Systems

Founded in 2006 as a spin-off from the University of Cantabria in Spain, Apria Systems works in environmental and chemical engineering. Their projects cover separation, purification, waste recovery, and clean energy. Project engineer Andrés Del Castillo Martín runs the additive manufacturing side, designing end-use 3D printed parts to fit each client's needs.

The Challenge: CNC Was Too Slow and Too Expensive for Custom Work

Before adopting 3D printing for manufacturing, Apria relied on CNC machining. CNC works well for simple shapes, but Apria's projects need complex forms and frequent design changes. Each client has different specs, materials, and tolerances.

CNC was costly for low-volume runs, and lead times made quick iteration hard. When a part needed changes after testing, the whole process restarted. For a company building one-off and small-batch parts, it was a poor fit.

The Solution: UltiMaker S6 for End-Use Production

Andrés chose the UltiMaker S6 for its open filament system. The team picks the right material for each job rather than being locked into one supplier. He runs the full UltiMaker workflow: slicing files in UltiMaker Cura and tracking prints remotely through Digital Factory.

"With the UltiMaker S6 printer, it's possible to create new applications we couldn't do before."

The open material system was a key factor. Apria prints with both UltiMaker and third-party filaments. For parts needing heat and wear resistance, Andrés uses Nylon CF Slide. For standard parts, PLA keeps costs low and print times short.

The Results: Real Parts in Real Applications

UltiMaker's case study highlights several parts Apria now produces in-house:

• Custom cooling cone for an annular UV lamp. Directs airflow through a glass tube and across the lamp's LEDs. Printed in PLA, replicated 8 times with a total print time of 21.5 hours.

• Internal component and protective casing for a UV lamp. Supports the glass end of the lamp, holds the aluminium LED mount, and secures the cooling fan. Printed in Nylon CF Slide for temperature and wear resistance. This is a true end-use part, designed to the client's exact specifications.

• Custom protective fan cover. Printed in white PLA with the company logo. Print time: 1.5 hours.

"3D printing saves time and money, as we can print exactly the amount that we need."

Every one of these parts would have needed CNC machining before. Now Andrés prints them in-house, iterates the design as needed, and produces only the amount required. No minimum orders. No weeks of waiting. This is 3D printing in the manufacturing industry at its most practical.

What This Means for Australian Businesses

Apria's story is relevant to any Australian business producing 3D printing custom parts in small volumes. If you outsource one-off or short-run parts to machine shops, you face the same friction: long lead times, high setup costs, and slow iteration.

The UltiMaker S6 ($14,975 AUD) is the same printer Apria uses. It supports hundreds of materials, from basic PLA to nylon and carbon fibre. For teams needing more throughput, the UltiMaker S8 ($18,975 AUD) is the next step up.

"I would strongly recommend the UltiMaker S6 to existing customers and new ones."

Want to bring custom part production in-house? Request a quote or read our 3D printer cost guide for Australia to compare pricing across every tier.

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3D Printer 3D Printer Materials 3D Printers additive manufacturing Manufacturing rapid manufacturing UltiMaker Ultimaker Cura Ultimaker Digital Factory Ultimaker s6