Custom production of prestigious items for global brands places high demands not only on appearance, but above all on technical execution, production repeatability and long-term structural stability. This was precisely the type of project cotu® delivered for UGO! Media, an agency producing awards for its client, Škoda Auto.
Project Brief
The aim of the project was to create original and prestigious awards for the winners of individual categories as part of Škoda Auto’s internal awards programme. The awards had to reflect the brand’s corporate colours (Emerald Green and Electric Green), convey a premium feel and be structurally prepared for series production with straightforward personalisation.
The client supplied a technical drawing and design concept, based on which cotu® provided:
- complete 3D modelling,
- production technology design,
- structural optimisation to ensure stability and simplify repeat production,
- final production and assembly.
The project also included a version intended for an international market, distinguished by a different colour scheme.
Technical and Production Objectives
The main technical and production objective was to design an award that met the premium standards of a global automotive manufacturer in terms of both appearance and quality of execution. A key requirement was a high-quality surface with no visible traces of the production process, even under close inspection of the finished product.
The structural solution also had to provide sufficient mechanical stability despite the award body’s tilted geometry, which places greater demands on weight distribution and overall balance. Another important consideration was preparing the design for series production with minimal variation between individual pieces, ensuring consistent quality over the long term.
The structural optimisation also addressed the mounting of the acrylic panels. We designed a mechanical snap-fit system that eliminates the need for bonding or additional alignment during assembly. Each panel features a machined groove, while the award body incorporates a precisely matched protrusion. This combination guides the panel into a precisely defined position and holds it securely at the required angle.
The result is high positioning accuracy, significantly simpler assembly and lower production costs, while maintaining the highest visual and structural quality for every piece.
The brief also required the acrylic elements to achieve a glass-like visual effect. The award therefore could not feel lightweight or plastic-like, but instead had to feel substantial and premium, in keeping with its purpose.
Technologies and Materials Used
Technology
- Phrozen MEGA 8K V2 3D printer – production of the award body and logo
- CNC machining of acrylic – production of clear and coloured panels
Materials
- Forward AM Ultracur3D ST 45 Resin – 3D printing of the award body and logo (selected to ensure accuracy and a high-quality surface finish)
- Clear acrylic – decorative panels with a glass-like appearance
Structural Solution and Optimisation
The award body is designed in a tilted position, which enhances its visual dynamism but also places greater demands on the mechanical stability of the entire structure. During production, it became clear that the weight of the CNC-machined acrylic panels exceeded the load capacity of the originally designed lower support section, making further structural optimisation necessary.
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The award body was produced using SLA 3D printing on a Phrozen MEGA 8K V2 printer. Its large build area made it possible to print the sizeable component in one piece without supports. This approach was essential not only for surface quality, but also for dimensional accuracy: eliminating supports preserved clean surfaces without support marks and simplified subsequent post-processing.
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The 3D printing material selected was BASF Ultracur3D ST 45, a tough urethane photopolymer designed for SLA technologies. It was chosen for its mechanical strength, toughness and dimensional accuracy, which are essential when producing larger components with integrated structural features. These properties made it possible to design an internal cavity for a steel weight of approximately 300 g, precisely shaped to match the geometry of the printed body.
The weight is secured with four screws, remains completely concealed within the structure and is covered by the bottom acrylic panel, so it does not interfere with the award’s exterior design. As a result, the finished trophy reaches a total weight of almost 1 kg, significantly reinforcing its substantial, premium character.
The entire structure was designed around a standardised base optimised for series production while maintaining consistent quality. It also enables rapid personalisation of individual pieces by replacing the dedication panel, without modifying the core structure or production process.
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Benefits and Added Value of the cotu® Solution
The solution designed by cotu® delivered a technically stable and structurally well-engineered product that retains its strength and balance despite the unconventional geometry of the award body. Combining SLA 3D printing with precise post-processing achieved a high-quality surface finish that meets the standards expected of prestigious, premium products.
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The standardised design enables efficient low-volume production with consistent quality across individual pieces, while also allowing rapid personalisation without changes to the core structure. Another major advantage is the end-to-end delivery of the project, from preparing the 3D data to final assembly, giving the client a single technical partner throughout the entire process.
Project Summary
The project for UGO! Media and Škoda Auto demonstrates that SLA 3D printing combined with conventional manufacturing technologies is an effective solution not only for prototypes, but also for prestigious finished products where detail, stability and visual quality are essential.
Thanks to its technical expertise and experience in low-volume production, cotu® delivered a solution that meets the exacting standards of a global brand while remaining efficient to manufacture and repeat in the future.
Are you looking for a technical partner for custom or low-volume production where accuracy, stability and surface quality are critical? Contact us to discuss the right solution for your project.