Metafora 3D prints great-looking prototypes, but it’s the ability to refine them through functional iterations that is the behind-the-scenes advantage of 3D printing.

“Having a 1:1 scale prototype that is very similar to the final result is important to make any customer understand what the final product will look like,” says Pedulli. “For us, the possibility to print a component, test it, modify it, and reprint it until an optimal result is found, is what makes 3D printing so special.”

And at a little over $2,000, the Zortrax M200 is an affordable investment for a small firm.

“3D printers are incredible tools that greatly facilitate the creative process, especially for those who do not have the resources to invest in large productions,” says Pedulli. “Some time ago, to obtain a prototype with a complex shape, it was necessary to invest a lot of resources (especially time) to be able to verify its lines, details, and dimensions.”

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One of the latest ambitious projects Pedulli has tackled is Eary, a home security earthquake warning system. It would be small and attractive enough to be installed in any home.

The idea to create a comprehensive, easy-to-use, and beautiful seismic warning device came to Pedulli after his trip to Japan, where he experienced a massive earthquake. His research found that the technology is available to warn people about earthquakes. There are also technology solutions for locating earthquake victims in the aftermath and communicating with emergency workers. The only piece missing was a system integrating all these technologies into a few simple, elegant devices everyone could install at home.

Eary consists of a small camera that can be placed near sensitive points in the house, such as doors and windows, a control device, and a mobile application.

Sketches and digital visualizations helped to design the initial appearance of Eary, but it was the 1:1 scale model made with FDM 3D printing that enabled the design team to further streamline the product. The prototype material used was Z-HIPS filament (from Zortrax), a high impact polystyrene modified to provide a semimatt finish with no post-processing. The Zortrax M200 uses proprietary Layer Plastic Deposition Plus (LPD Plus) technology to 3D print high-temperature filaments with soluble support structures.

Pedulli and his young team of engineers learned and used 3D printing for rapid prototyping while they were students at the Polytechnic University of Milan, but today it’s different, he says. “Now 3D printing is a fundamental part of our process and we approach it in a much deeper way than at university. We use it for every project that requires a 3D element, a dimensional test, or a proof of concept.”

The team is continuously pushing the boundaries of what their printer can do. “Sometimes between projects, we spend some time creating small items, objects, and various complex elements,” says Pedulli. “This helps us to freely experiment with ideas. It’s very important for us to keep experimenting and push our boundaries far from everyday routine-projects.”

Currently, the design of the Eary system is only a concept in search of a buyer, but Pedulli says the chances of turning this idea into reality are higher with a great-looking functional prototype made possible with 3D printing. “It is still possible to make a customer fall in love through a beautiful 2D photorealistic render, but a concrete and physical 3D test makes the final experience certainly more complete.”