Flashforge “Veteran” Drives the Rise of a North American 3D Printing Farm: From Garage Startup to a Daily Output of 2,000 Parts

Amid the wave of digital transformation in manufacturing, 3D printing farms are rapidly emerging as an innovative and highly efficient production model. Back in 2016—when the concept was far from mainstream—American engineer Kason keenly recognized the industrial potential of 3D printing and founded i-SOLIDS, a company dedicated to production-oriented additive manufacturing. Eight years of steady growth have since transformed i-SOLIDS into one of the largest and most influential 3D printing farms in the United States.

Today, i-SOLIDS operates more than 140 3D printers spanning multiple processes, including FDM, resin, and powder-based technologies. Among them, rows of Flashforge Creator Pro machines—still running reliably—stand as an iconic presence in the printer lineup. In an era flooded with new equipment, this “not-so-new” model remains a core workhorse. Kason notes that the Creator Pro not only witnessed the company’s growth but also marked the beginning of his close partnership with Flashforge.

From a Single Creator Pro to a 20,000-Square-Foot Production Facility

“My first encounter with 3D printing was in 2015, purely out of personal interest. But as print quality improved and costs declined, I realized the technology had immense potential for commercial manufacturing,” Kason recalls. In 2016, he launched i-SOLIDS as a side project; by the end of 2017, demand had grown enough to move operations from his home to a warehouse, officially turning 3D printing into his full-time business.

The early purchase of a Creator Pro proved pivotal—its enclosed FDM design was rare at the time and particularly well-suited for batch production using mid- to high-performance materials such as ABS and ASA. This capability enabled i-SOLIDS to enter the market with high-strength industrial parts.

By July 2025, with business expanding rapidly, i-SOLIDS relocated to a brand-new 20,000-square-foot facility, capable of housing over 400 FDM machines, with infrastructure and utilities prepared for future growth.

The Keys to a Successful Printing Farm: Stability, Efficiency, and Consistent Output

“We chose Flashforge not only for its reliable performance and outstanding value, but also for its exceptional after-sales support and long-term service,” says Kason. The Creator Pro’s decade-long production run and readily available spare parts have significantly reduced maintenance costs and ensured a strong return on investment over the machines’ full lifecycle.

Currently, i-SOLIDS still operates 64 Creator Pros, many of which have been running continuously for six years. “While we’ve added newer models, the Creator Pro’s stability, precision, and versatility keep it indispensable in core applications.”

Having evolved from producing replacement parts, models, and gifts for individual orders to supplying large-scale production for automotive, aerospace, medical, and consumer electronics industries, i-SOLIDS now manufactures enclosures, brackets, jigs, and more—some from high-performance materials like PEEK and Ultem. The farm’s daily capacity exceeds 2,000 parts, with actual output adjusted to part complexity.

Three People Managing 140 Machines: Lean Management in Action

Kason shares that 2018, the first full year, was challenging, yet generated about $180,000 in revenue with a 20% profit margin. Since then, the company has maintained an average annual growth rate of around 120%, focusing on profitability rather than unchecked expansion. By 2025, growth has been entirely organic, without external funding. The new facility can house more than 400 FDM printers, leaving room for further expansion.

With growth, efficient management became critical. “As a sole operator, I could adapt instantly without formal processes. But as the team expanded, structure became essential. The biggest challenges often come from political or environmental factors—pandemics, conflicts, inflation, supply chain disruptions—things you can’t fully predict in business forecasts. Yet every challenge is also an opportunity to showcase additive manufacturing’s adaptability.”

Today, i-SOLIDS employs 25–30 people in sales, quality control, post-processing, and engineering, with only three dedicated to running the FDM farm. They work in rotating 24/7 shifts to keep operations smooth. “We believe manufacturing profitability hinges on lean, efficient processes. That’s why we focus on clear, automated workflows to achieve high ROI. For example, our in-house software enables paperless tracking of every machine’s production status.”

Expanding Multicolor FDM Printing as a New Growth Engine

While strengthening its large-scale production capabilities, i-SOLIDS is also exploring new applications. Recently, the team introduced the Flashforge AD5X to expand into multicolor FDM printing, now in rigorous testing.

“We used to rely on powder-based processes for full-color printing, but advances in FDM multicolor technology make it a cost-effective alternative. Many customers don’t need complex patterns—just a logo, QR code, or color marking on products—and the AD5X fits that niche perfectly.”

Kason adds that the new facility’s space, power, and network infrastructure create ideal conditions for large-scale deployment of multicolor FDM, making the AD5X a core part of the next strategic phase.

Advice for Entrepreneurs: Precision, Patience, and Long-Term Thinking

Kason believes the 3D printing farm sector is entering a golden era. He urges entrepreneurs to start small, prioritize quality and customer feedback, build robust supply chains, and constantly evaluate their offerings from the customer’s perspective.

“Entrepreneurship is far from easy. Many see the spotlight of success but overlook the system building and relentless execution behind it. To succeed, you need clear standards for yourself and your team—and a long-term mindset.”

Conclusion: Flashforge Powers a Scalable New Model for Additive Manufacturing

From a single Creator Pro to a fleet producing thousands of parts daily, i-SOLIDS has proven the feasibility and sustainability of large-scale additive manufacturing. Throughout this journey, Flashforge equipment—renowned for its stability, durability, and value—has served as the “engine” driving long-term growth.

This success story offers a valuable reference for global manufacturers navigating digital transformation and illustrates how 3D printing can truly evolve from a prototyping tool into a production powerhouse.