Enterprise Defense
“If we used injection molding, the initial costs would be astronomical.”
MMMichal MalinskýProduct Manager, Compelson
Compelson
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Compelson case study in numbers
Compelson builds digital forensics tools in Prague, with software used by law enforcement in over 160 countries. When smartwatches arrives without standard data ports, extracting evidence requires custom hardware. Because new watch models are released every year, traditional manufacturing was too slow and expensive. Compelson relies on 3D printing to keep up instead.
- 59people building tools in Prague
- 160+countries using MOBILedit
- 1.5years of development
9major casing versions
9 major versions of the Samsung reader casing were prototyped over a year and a half, each with numerous sub-versions.
Creating interfaces for portless smartwatches
- ProblemForensic investigators require physical access to extract data from devices. Unlike mobile phones with standard data ports, smartwatches often lack cables entirely. Manufacturers frequently alter design details with new models, requiring the forensic adapters to be updated annually for every new smartwatch edition.
- SolutionInjection molding is not a viable business model for this application. Creating a mold for each adapter involves high initial costs for components that become obsolete within a year. Instead, Compelson relies on 3D printing to manufacture the specialized readers, adapters, and casings directly in-house.Printed onPrusa CORE OnePETG
- ValueThe catalogue of watches stopped being a catalogue of molds. A new model means a new file, not a new tool, and the adapters ship inside the MOBILedit Forensic kit that investigators carry into the field.
“With new watch models released every year, we would need a new mold each time, which would be like throwing money out the window. 3D printing is a much better solution for us.”
Michal Malinský, Product Manager at Compelson
Iterative prototyping for reader casings
- ProblemDesigning a reliable physical interface for a smartwatch requires overcoming complex technical challenges and undocumented manufacturer design decisions. Developing an accurate fit requires extensive physical testing and validation.
- SolutionThe Samsung watch reader underwent a year and a half of development, resulting in nine major versions of the casing and numerous sub-versions to test different features. The team uses PLA for initial prototypes before transitioning to more robust materials like PETG and Polycarbonate Carbon Fiber for the final, field-ready production parts shipped to customers.Printed onPrusa CORE OnePrusament PC-CF
- ValueIteration stopped being the expensive part of the project. The team could solve the hard problems, including the ones created by other manufacturers’ design decisions, by trying, not by budgeting for a mold.
Rapid manufacturing for urgent forensic operations
- ProblemThe Czech Military Police urgently needed to extract data from a rare first-generation Galaxy Watch. The required connector was not available in standard kits. Traditional manufacturing for a single custom part involves weeks of lead time and prohibitive costs.
- SolutionCompelson designed a fully functional custom connector, printed it in under 20 minutes, and delivered it for use the next day. The company also distributes 3D files directly to customers, allowing them to print replacement or newly developed adapters on their own machines to ensure they always have the right tools.Printed onPrusa CORE One
- ValueA one-off part stopped being a project. For an agency, that is the difference between evidence retrieved this week and a device that stays closed.
Could 3D printing cut the tooling out of your product?
Tell us what you build. We will come back with the machines, the materials and the parts other hardware teams print first.
Still not sure where 3D printing fits your production?
See what other enterprise companies print, an architecture studio, a collider, a hangar, a car plant.
Customer story Seco Tools
Seco Tools put a 1:1 cutting tool on Škoda’s table in four days
The Swedish tool maker’s Czech branch was asked to unblock a gearbox line where one part needed three ISO tools and almost 51 seconds. A single combined tool, printed 1:1 before it was ever cut, brought the operation to 40.2 seconds, Škoda Auto’s figure, on Škoda Auto’s line.
- 4 daysassignment to 1:1 printed model
- 10.7 scut from Škoda’s cycle time
- €10,650saved at Škoda in a year
“Thanks to 3D printing, I rediscovered my passion for innovation and industrial tool design.”
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Your team’s questions, answered
What creators, engineers, and workshop leads usually ask before the first print.
Forensics Investigator
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Hardware Engineer
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