Beyond the Mold: How Evolve’s STEP Technology Revolutionizes Production, Challenging Injection Molding

Injection molding has long been a titan in the manufacturing world, boasting an estimated market value of $187 billion in 2022. Its ubiquity stems from its ability to produce vast quantities of identical parts with high efficiency. However, the landscape of production is rapidly evolving, with additive manufacturing (AM) emerging as a powerful contender, capable of rivalling and even replacing traditional methods like injection molding. This transformative potential was the core focus of our insightful webinar, “Beyond the Mold: Achieving Quality Additive Production That Rivals Injection Molding,” held on April 18th. We were privileged to host industry leaders Andy Harkison, Director of Product Management, and AJ Frisell, Advanced Application Engineer, from Evolve Additive Solutions. They delved deep into how additive manufacturing, specifically Evolve’s groundbreaking technology, presents a viable and superior alternative for a growing range of production applications.

The discussion centered on Evolve’s Selective Thermoplastic Electrophotographic Process (STEP) Technology. Developed from the ground up with production applications and scalability in mind, STEP is designed to bridge the gap between prototyping and high-volume manufacturing. Unlike many conventional additive processes, STEP delivers parts with isotropic mechanical properties, exceptional surface finish, and tight tolerances, directly comparable to or even exceeding those achieved through injection molding. The webinar provided an in-depth analysis and compelling comparison of the mechanical performance, fidelity, and accuracy of STEP-produced parts against those manufactured using injection molding and other additive methods. Furthermore, the experts highlighted numerous successful use cases and innovative applications where the unique combination of STEP’s uncompromised quality and its inherent production capacity offers an ideal solution for modern manufacturing challenges.

In an era demanding agility, customization, and robust supply chain solutions, the ability to produce end-use parts with additive manufacturing at scale is a game-changer. STEP technology addresses critical limitations often associated with 3D printing for production, such as part strength variability, surface quality issues, and throughput. By leveraging an electrophotographic process similar to 2D printing, STEP precisely deposits thermoplastic materials layer by layer, enabling rapid fabrication of complex geometries with engineering-grade plastics. This innovative approach allows manufacturers to bypass expensive tooling, reduce lead times significantly, and introduce design iterations with unprecedented speed, ultimately accelerating product development cycles and time-to-market. The webinar illuminated how this technology empowers companies to rethink their production strategies, moving towards more flexible, cost-effective, and sustainable manufacturing paradigms.

The comprehensive comparison presented by Evolve’s experts showcased how STEP technology is not merely an alternative, but often a preferred method for specific production scenarios. For instance, in applications requiring customized components, intricate designs, or low-to-mid volume production runs, the economic and operational advantages of STEP become profoundly apparent. The ability to produce functional prototypes and end-use parts on the same platform, using the same materials, ensures seamless transition from design to final product. This level of consistency and control is invaluable for industries such as automotive, aerospace, medical devices, and consumer electronics, where performance, reliability, and precision are paramount. Participants gained valuable insights into the tangible benefits of integrating STEP technology into their manufacturing workflows, including enhanced product performance, streamlined supply chains, and greater design freedom previously unattainable with conventional methods. See the replay below to experience these insights firsthand!

Meet Our Expert Speakers: Shaping the Future of Production

Andy Harkison, as the Director of Product Management at Evolve Additive Solutions, plays a pivotal role in steering the company’s strategic direction for its innovative STEP technology. His responsibilities encompass driving product requirements and overseeing the commercialization efforts for systems, software, materials, and comprehensive parts production services. Andy’s profound expertise is rooted in an extensive background as a go-to-market leader across various high-tech manufacturing sectors, including semiconductor, material testing, and the rapidly advancing additive industries. This diverse experience provides him with a unique perspective on the challenges and opportunities in advanced manufacturing. He holds a Bachelor of Arts in Physics from Carleton College and a Master of Science in Management of Technology from the University of Minnesota, academic achievements that underscore his deep understanding of both the scientific principles and the commercial realities of cutting-edge production methods. Andy’s insights during the webinar were crucial in outlining the strategic advantages and market positioning of STEP technology in the competitive manufacturing landscape.

AJ Frisell, an Advanced Application Engineer at Evolve Additive Solutions, is at the forefront of optimizing the performance and application of STEP technology. His work spans the entire additive manufacturing process, from initial file preparation to the final printed part, with a dedicated focus on Design for Additive Manufacturing (DFAM). AJ’s expertise in DFAM is critical for ensuring that parts produced with STEP achieve optimal quality, structural integrity, and cost efficiency, making them truly competitive with injection molded components. He brings invaluable proven experience from the medical device manufacturing sector, a field renowned for its stringent quality requirements, across both traditional and additive manufacturing disciplines. AJ’s practical, hands-on knowledge is complemented by a Design for Additive Manufacturing certificate from Dunwoody Technical College and a Bachelor of Arts in Marketing from the University of Montana. His ability to translate complex technical capabilities into practical, beneficial applications for clients was evident throughout the webinar, offering attendees actionable strategies for integrating STEP into their production lines.

Madeleine Prior serves as the English Content Specialist at 3Dnatives, a premier international online media platform dedicated to 3D printing and additive manufacturing. In her essential role, Madeleine is responsible for curating and defining the content that 3Dnatives delivers to its vast English-speaking audience. She is instrumental in ensuring readers receive the most current, relevant, and impactful news and analyses from the additive manufacturing sector and its far-reaching implications across industries. Her presence as a moderator for the webinar underscored 3Dnatives’ commitment to bringing leading-edge discussions and expert insights to the global AM community. Through her efforts, 3Dnatives continues to be a vital resource for professionals, enthusiasts, and newcomers alike, fostering a deeper understanding of how technologies like Evolve’s STEP are transforming industrial production and beyond.

The conversation about replacing parts made with injection molding with additive manufacturing is becoming increasingly critical. We invite you to share your thoughts: Did you attend this groundbreaking webinar? What are your perspectives on the ongoing evolution of production methods and the role of additive manufacturing in challenging long-established techniques? Let us know in a comment below or join the discussion on our LinkedIn, Facebook, and Twitter pages! Don’t forget to sign up for our free weekly newsletter here, to receive the latest 3D printing news straight to your inbox! You can also find all our compelling videos and webinars on our YouTube channel, offering a visual dive into the world of additive manufacturing innovation.