Ostberg Partners with CreatBot for Fan Development
Transforming HVAC R&D with Large-Format 3D Printing
Abstract
Swedish HVAC leader Ostberg used the CreatBot D600Pro2 HS to rapidly produce full-scale fan prototypes, cutting development time by 70% and costs by 65%. This demonstrates the impact of high-temperature, large-format 3D printing on industrial R&D.
Customer Challenge: Overcoming HVAC R&D Pain Points
Company Background
Ostberg Group, founded in 1947, is a leading European manufacturer of ventilation systems for commercial and residential applications, renowned for energy efficiency and advanced technology.
Core Requirements
Produce full-scale 1:1 fan models for aerodynamic testing
Key material performance requirements:
Withstand high-temperature airflow of 80°C
Maintain structural integrity at impeller speeds over 2,500 rpm
Survive over 100 hours of high-frequency vibration testing
Complex structure realisation:
Integrated impeller and airflow duct, difficult and time-consuming with traditional CNC machining
Cost and time pressures:
Metal tooling for single prototypes exceeds $8,000, with delivery cycles of 3+ weeks
Solution: CreatBot D600Pro2 HS in Action
Equipment Configuration
CreatBot D600Pro2 HS Industrial 3D Printer
Core Features
Large build volume: 600 × 600 × 600 mm (Top 5% in the industry)
Dual high-temperature nozzles up to 420°C, compatible with engineering materials such as ABS, ASA, Ultra PA, PET-CF
High-precision industrial linear rails
Active temperature-controlled chamber: 70°C
Material Selection: Ultra PA-CF (Carbon Fibre Reinforced Nylon)
The fan had four core requirements:
80°C high-temperature airflow resistance, 2500 rpm centrifugal tear resistance, over 100 hours vibration stability, and Ra < 10 μm for air channel precision.
To meet these requirements, Ultra PA-CF was selected:
Heat resistance: 197°C ensures structural integrity under high-temperature airflow
Strength: 61 MPa with carbon fibre resists centrifugal stress
Durability: +40% impact toughness via interlayer reinforcement, vibration tested
Precision: Polished air channels achieve Ra = 6–8 μm for optimal airflow
Performance: 420°C nozzles and 70°C chamber maximise UltraPA-CF potential
Implementation Process
Fan 3D model optimisation → Material selection: Ultra PA-CF → Parameter settings: Layer height 0.2 mm → 32-hour one-piece printing
Performance Comparison: Breaking Traditional Manufacturing Limits
| Metric | Traditional CNC Post-Processing | D600Pro2 HS 3D Printing | Improvement |
|---|---|---|---|
| Delivery Time | 22 days | 6 days | ↑73% |
| Design Iterations | ≤2 per cycle | 5 per week | ↑150% |
| Material Utilisation | 45%–60% | 98% | ↑63% |
Industry Impact & Insights
Product Development Revolution
1:1 functional prototyping with zero scaling errors
Integrated impeller-volute manufacturing for real operating conditions
Upgraded Manufacturing Mode
From “Design → Outsource → Wait” to “Design → Print → Test”
Engineers operate independently, ensuring IP protection
Sustainable Development
85% less metal waste during R&D
12 tons lower annual carbon emissions per device vs outsourcing
Technology Expansion Directions
Based on successful fan prototype validation, Ostberg will continue to expand:
Functional integrated printing, including smart housing with embedded sensor channels
High-performance material applications using carbon fibre reinforced nylon (PA-CF) impellers
Small-batch customised production, achieving around 50 units per month using equipment clusters
Conclusion
The Ostberg case clearly shows that industrial large-format 3D printing has moved beyond a concept validation tool into a practical solution for full product development.
With compatibility across engineering-grade materials, precision industrial architecture, and an open production ecosystem, the CreatBot D600Pro2 HS is becoming a key part of R&D infrastructure across HVAC, energy, and heavy industry sectors.
This partnership goes beyond prototype production. It reflects a shift towards faster, more flexible, and more efficient product development, supported by end-to-end processes from model optimisation through to final production-ready parts.