3D printing is increasing in popularity among cottage gear makers who are innovating new ultralight gear starting in small quantities. We asked a few GGG business owners to tell us in their own words why they 3D print parts for their designs, how the technology has set them apart, and how it has allowed them to proliferate their designs.
Laura at ADOTEC
"As Adotec is such a small company, 3D printing has allowed us to make small batch items that would otherwise require a large investment of capital for plastic injection molding at a standard manufacturing company. It's allowed us to create, test and modify our product ideas in a way that is flexible, quick and cost effective."
Tyler at Rex Creations
"I think a really popular reason that small businesses are using 3D printers to produce plastic components is that it's a fixed tooling cost: it's one tool, and if you ever want to change your part design or produce a completely different type of component, you don't have to buy a whole new one which is great."
Ray at Igneous
"3D printing has been a game-changer for Igneous (formerly known as Common Gear), allowing us to manufacture products affordably in small quantities. Traditional manufacturing techniques often require expensive tooling, which limits production to high-volume or high-cost items. With 3D printing, we're able to bypass these limitations and create specialized gear tailored to the ultralight backpacking community.
"One prime example is our UL Repair Kit. Utilizing 3D printing, we've designed it with a hollow core to significantly reduce weight without compromising strength. If we had used traditional manufacturing methods, the kit would have to be solid, adding unnecessary weight that goes against ultralight principles.
"While 3D printing has accelerated our product design and brought many benefits, we've found that not all products are best served by this method. As we've grown and reached higher production volumes, we're transitioning some items to alternative manufacturing processes to enhance their performance further. This shift is only possible because of the scale we've achieved, and it reflects our commitment to continuously improving our gear for the best possible backpacking experience."
Jeremy at Jereko Gear
"I choose 3D printing for producing my gear for three main reasons: sustainability, efficiency, and innovation. First, it's a low-waste, cost-effective solution. While 3D printing generates minimal plastic waste, it’s far less than traditional manufacturing methods, as I can design and print gear with precision to reduce excess material. This also allows me to avoid the costly upkeep of traditional machinery, keeping my products affordable. Plus, all plastic waste is repurposed into new items, reinforcing our commitment to sustainability.
"Second, 3D printing offers unparalleled production speed and creative freedom. With advanced printers, I can quickly produce gear and develop new designs, significantly reducing the time between concept and fulfillment. This agility means I can respond swiftly to customer needs and bring innovative gear to market faster.
"Finally, it aligns with industry trends, but with a different approach. While many companies use 3D printing for cutting-edge products, they often rely on expensive methods that small businesses like Jereko Gear can’t afford. Instead, I focus on FDM (Fused Deposition Modeling) printing—affordable, practical, and often underestimated. Rather than chasing high-cost manufacturing for validation, I see FDM as a way to show that functional, high-quality outdoor gear can be made sustainably and affordably. My goal is to demonstrate the full potential of this technology to the outdoor community."
How to Support 3D Printing Innovators
From knife handles, to zipper pulls, to tape winders, to electric air pumps, there's some pretty rad 3D printed ultralight gear out there made by cottage brands these days. You can help support the continued use of 3D printing along with U.S. manufacturing and low-waste production practices by buying your next gear item from one of these cottage brands on GGG. Then tell your friends about it!
1 comment
Bob Najar
What would be really nice is a palm-sized air-mattress inflator made of lightweight plastic that is a rotary vane pump that would be manually operated (no batteries or charging!). The form factor would be similar to a fly-fishing reel, only slimmer.