Markforged Teams up with Black and Decker
“It is very feasible to leverage the Metal X platform in additively manufacturing the discussed actuator housing with very minimal capital and time investment.”
Introduction
Black and Decker put a Markforged Metal X printer to the test. They wanted to cut costs on two commonly used parts; an actuator housing for the PD45 Hydraulic Post Driver and a wheel shaft for the PG10 Profile “Frog” Grinder. If these two parts could be printed with additive technology, it could save them significant money on production costs. Parts printed on the Metal X have the potential to save industrial customers significant capital if utilized correctly. By designing intelligently for these machines, minimizing print time, and using off the shelf parts when possible, it’s possible to produce high-quality parts much more cost-effectively than subtractive manufacturing.
By replacing the wheel shaft with Markforged’s printed flange and shaft assembly, Stanley Infrastructure cuts their production lead time in half and saves between a quarter and half of their production budget for full volume manufacturing. However, since this part is a high wear component and the production volume for this grinder is low, the most lucrative use of the Metal X comes from the astronomical savings they get in one-off manufacturing. Replacing the inefficient-to-machine original part with a Metal X print yields 25x cost savings and 50x time savings on a single part manufacturing basis.
The Challenge
Stanley Infrastructure, a division of Stanley Black & Decker, needed a cost-effective solution for manufacturing low-volume, complex metal parts like actuator housings and wheel shafts. Traditional casting and machining methods were expensive, wasteful, and slow—especially for one-off or replacement components. The team faced challenges with excessive material waste, lengthy lead times, and costly batch-based production workflows.
The Solution
Stanley Infrastructure adopted the Markforged Metal X additive manufacturing platform to redesign and produce key components. By reengineering the actuator housing as a single-piece 3D-printed part and redesigning the wheel shaft to combine off-the-shelf components with printed parts, they significantly improved material efficiency and cut production costs. This approach allowed them to shift from traditional subtractive processes to streamlined, scalable, on-demand part production.
Implementation
Engineers at Stanley Infrastructure conducted rigorous performance and durability testing on Metal X-printed components, including drop and abuse tests. For the actuator housing, the original four-part assembly was consolidated into a single printed unit with no support structures. For the wheel shaft, the team replaced 90% waste machining with a hybrid method—using an off-the-shelf shaft and key combined with a 3D-printed flange. These design changes enabled efficient production tailored to low-volume needs.
Results
By implementing the Markforged Metal X, Stanley Infrastructure achieved significant performance and cost improvements. For the actuator housing, they saw manufacturing cost savings between 34% and 48% for full production runs, while single-part replacement yielded a remarkable 92% cost reduction and 95% time savings. Additionally, overall lead times for the part were cut by 69%. In the case of the wheel shaft, the redesigned hybrid part enabled 25x cost savings and 50x time savings for one-off manufacturing, while still offering 25% to 50% savings for full-volume production. The printed parts also proved to be 20% lighter and successfully passed rigorous durability and shock testing, validating their reliability for use in demanding industrial environments.
