Prototal Denmark supports Macula, a subsidiary of Litecom, in the serial production of polymer components for advanced lighting control systems used in the entertainment industry. By transitioning from in-house prototyping to Industrial 3D Printing, Macula was able to scale production rapidly while maintaining tight tolerances, high surface quality, and a fast time to market.
Litecom is a Danish company specializing in technical solutions for large-scale live productions, including international events such as X Factor, the Zulu Comedy Awards, and Eurovision. Building on their experience in live entertainment, Litecom identified a need for more advanced and flexible lighting control elements. This led to the creation of Macula, a subsidiary focused on developing and commercializing a new lighting control system for the entertainment industry.
The Challenge
During the initial development phase, Litecom produced prototypes using in-house FDM 3D printers. While suitable for early testing, this approach presented limitations:
- Insufficient tolerances and surface detail for end-use components
- Limited suitability for series production
- Constraints when scaling production to meet external demand
As product maturity increased and interest in the Macula system grew, Litecom required a manufacturing method capable of supporting production-grade quality and scalable volumes without introducing tooling delays or high upfront investments.
Manufacturing Approach
Following an initial evaluation of industrial additive manufacturing options, Litecom engaged with our Prototal site in Denmark to support the transition from prototyping to serial production.
Technology and Material Selection
- Industrial 3D Printing with the technology Selective Laser Sintering (SLS)
- PA 2210 FR, chosen for dimensional stability, durability, and flame retardant capabilities
- Post-processing including surface treatment and dyeing prior to delivery
Industrial 3D Printing in SLS enabled the Macula components to be produced with significantly higher precision and repeatability compared to desktop printing, while remaining suitable for series production.
Scaling to Serial Production
After several design iterations, demand for the Macula system increased rapidly. Using Industrial 3D Printing, Macula was able to:
- Increase production capacity without tooling changes
- Move directly from validated prototypes to serial production
- Respond quickly to market demand
This flexibility allowed the newly established subsidiary to enter the market without delays typically associated with traditional manufacturing ramp-up.
Key Advantages of Industrial 3D Printing
The use of Industrial 3D Printing supported Macula’s product development and production strategy in three key areas:
Design Freedom
Component geometry could be optimized for functionality without the constraints of traditional manufacturing methods, enabling greater integration and design efficiency.
Controlled Production Costs
Production costs remained predictable from prototype through to serial production, without the need for molds or tooling investments.
Fast Time to Market
The ability to move directly from design to production-ready parts enabled a short and efficient development cycle, supporting rapid market entry
Ongoing Production
Today, Prototal is responsible for the serial production of handles for the Macula system. The components are manufactured using SLS in PA2200, post-processed, dyed, and delivered to Macula for integration of electronics and final assembly.
This case demonstrates how industrial 3D printing can function as a primary manufacturing method for series-produced components in the entertainment technology sector. By combining scalable SLS production with consistent quality and design flexibility, Prototal supported Macula in moving efficiently from concept to market-ready product.
