Every custom product begins with a problem that needs solving. In this case, it started with a simple text message: “Hey, I have this idea for my paddleboard.”

At first glance, it sounded straightforward. However, as with most custom product design projects, the challenge was not the idea—it was executing it correctly. My sister, an avid paddleboarder, needed something specific: a waterproof, durable, and secure cup holder that could withstand splashes, sun exposure, and movement on open water.

That is exactly where custom product design and 3D printing shine. At Mettler Design, turning concepts into functional, manufacturable products is what we do best. This project perfectly demonstrates how thoughtful engineering, modern CAD tools, and advanced manufacturing can bring even small ideas to life.

Scoping the Project: Translating Vision into Requirements

Understanding the Real-World Use Case

Before opening any CAD software, the most critical step was project scoping. At Mettler Design, we emphasize understanding how a product will be used in the real world. This phase sets the foundation for success.

In this case, the “customer” wanted the cup holder to:

• Fit multiple water bottle and tumbler sizes
• Withstand water, sun, and outdoor exposure
• Attach securely using bungee cords
• Remain stable during motion
• Be produced in low quantities, not mass-manufactured

Although the conversation was informal, it covered everything required for a solid engineering brief. Because this was a custom, one-off project, the manufacturing strategy needed to stay flexible and cost-effective.

Once those requirements were clear, the design process could begin.

Turning the Idea into a Digital Model with SOLIDWORKS

CAD Design for Function and Durability

With requirements defined, the next step involved CAD modeling in SOLIDWORKS, a core part of Mettler Design’s product development workflow. CAD allows designers and engineers to visualize every aspect of a product before manufacturing begins.

The cup holder design needed to balance:

• Structural strength
• Lightweight geometry
• Ease of attachment
• Compatibility with multiple cup sizes

Slots were integrated into the model to accommodate bungee cords, ensuring the holder could be tied down securely without wobbling. Every curve, wall thickness, and opening was intentional.

Because SOLIDWORKS allows precise control over dimensions and tolerances, the design could be optimized long before any physical part existed. As a result, costly redesigns were avoided later.

Choosing the Right Manufacturing Method

Why 3D Printing Made Sense

Designing a product is only half the journey. Manufacturing decisions can make—or break—a project.

For large-scale production, injection molding or CNC machining often makes sense. However, for low-volume custom parts, those methods come with high setup costs. That is why 3D printing became the clear choice.

With 3D printing, Mettler Design can:

• Produce functional end-use parts
• Avoid expensive tooling
• Iterate designs quickly
• Manufacture small batches efficiently

Still, not all 3D printing methods are equal. Material choice and print technology matter just as much as the design itself.

Partnering with A3D Manufacturing for Advanced 3D Printing

Leveraging Expertise and Technology

To ensure the best possible outcome, collaboration was essential. Mettler Design partnered with A3D Manufacturing, specialists in advanced additive manufacturing.

After reviewing the CAD model, they recommended:

• Multi Jet Fusion (MJF) 3D printing
• PA12 nylon material

PA12 is known for its:

• High durability
• Impact resistance
• Dimensional accuracy
• Suitability for outdoor applications

Additionally, MJF printing produces parts with excellent surface quality and consistency. As a result, the printed cup holder matched the SOLIDWORKS design down to the millimeter.

Adding a Durable and Eye-Catching Finish

Cerakote for Performance and Style

While performance came first, aesthetics still mattered. To elevate the final product, a Cerakote finish was applied.

Cerakote is a ceramic-based coating used across demanding industries, including automotive and aerospace. For this paddleboard cup holder, it delivered two key benefits:

• Enhanced resistance to moisture and UV exposure
• A bold red, white, and blue custom finish

Not only did the coating protect the part, but it also gave the product a unique visual identity—something many off-the-shelf accessories lack.

From Prototype to Real-World Testing

Evaluating Fit, Stability, and Performance

Once the parts arrived, testing began immediately. First, multiple bottles and tumblers were placed in the holder. Each fit securely. The bungee slots held tight. The part felt solid.

However, the real test happened on the water.

Out on the lake, the cup holder performed exactly as intended. Even through choppy conditions and sharp turns, it stayed in place. More importantly, it improved the paddleboarding experience by keeping hydration within easy reach.

The Cerakote finish also held up well, showing no signs of wear from sun or water exposure.

Key Lessons from This Custom Product Design Project

The Power of Collaboration

One major takeaway from this project was the importance of collaboration. Mettler Design’s engineering expertise combined with A3D Manufacturing’s additive manufacturing knowledge resulted in a better product than either could have achieved alone.

Iteration Drives Better Outcomes

Another critical lesson involved iteration. Each stage—from scoping to design to testing—required refinement. Because 3D printing supports rapid iteration, improvements could be made without excessive cost or delays.

This mindset applies to all custom product design projects, regardless of size.

Scaling the Design: From Custom Part to Consumer Product

Although this project focused on a small production run, it also highlighted future opportunities. If demand grows, the same design could transition to injection molding for mass production.

At Mettler Design, we often help clients navigate that transition by:

• Refining designs for manufacturability
• Evaluating tooling costs
• Selecting scalable materials
• Planning production workflows

Until then, additive manufacturing remains the perfect solution for low-volume, high-value products.

The Bigger Picture: The Future of Custom Manufacturing

The paddleboard cup holder may seem like a small project, yet it represents a much larger shift in manufacturing. Today, custom product design and 3D printing allow businesses and individuals to create tailored solutions without relying on traditional mass production.

As technologies continue to evolve, the barrier between idea and reality keeps shrinking. Whether you are designing outdoor gear, industrial components, or consumer products, the process remains the same:

• Clearly define the need
• Design with intention
• Choose the right manufacturing method
• Collaborate with experts
• Iterate and refine

That is how Mettler Design helps clients turn ideas into real, functional products—one project at a time.

Ready to Bring Your Idea to Life?

From concept development and CAD modeling to manufacturing strategy and production support, Mettler Design specializes in custom product design that works in the real world.

If you have an idea—big or small—and want to explore how custom product design and 3D printing can make it a reality, now is the perfect time to start.