How Old Town uses 3D printing to innovate

Old Town has been in business since 1898. Staying relevant for so long means that a company must adapt to meet the customer’s ever-changing needs. As a Johnson Outdoors brand, understanding the customer and improving their experience in the great outdoors is core to who we are.

The engineering team at Old Town continue to seek opportunities to improve and expand the technology used to produce the highest quality watercraft in the industry. With the advancement of manufacturing technologies, such as 3D printing, Old Town is able to expedite the innovation process.

Old Town has utilized 3D printing technology for nearly 20 years. Early on, 3D printers were used for special projects due to the cost and availability of quality machines. Like with other tech, the costs decreased over time. And, in many ways, provides a great value by reducing sourcing costs and lead time. Today, 3D printing is an important tool used daily by Old Town engineers.

So what is 3D printing? The 3D printing process starts with generating a three-dimensional computer model using special engineering software. The software file is loaded into the printing machine, which uses material to construct a three-dimensional model object.
 

There are different types of materials used for 3D printing, such as thermoplastics and metals. Depending on the project end goal, the material used changes the attributes of the final model. Some thermoplastic materials produce soft, pliable models, while others produce stiff, rigid models (especially if it is infused with carbon fiber). As the technology has advanced, engineers have the ability to 3D print metal parts, too.

Prior to adopting 3D printing at Old Town, parts were largely sourced from external vendors, which was time-consuming and laborious. Engineers would draft part specifications, seeking external vendors to produce or source. It could take months to receive the parts to test and validate, adding longer lead times to the overall project. The engineers would rely heavily on vendor experience, photographs and computer-generated images. Now, with 3D printing capabilities, the engineering team simply tests on the fly, prior to sourcing the final product.

The amount of time it takes to 3D print a model, depends on the size of the part. For example, a deck fitting for a tank well bungee cord could take as little as 15 minutes to print, whereas larger components may take several days. Regardless, 3D printing greatly increases productivity and the speed at which Old Town brings a product to market.

Finally, 3D printing mitigates the risk of production errors. The technology allows engineers to test new parts out on the water as well as on the manufacturing floor, reducing potential design errors.

3D printing technology is just one of many tools used by Old Town to produce the most innovative watercraft in the world. The importance of innovation is highly valued in each brand that lives within the Johnson Outdoors family of brands. To read how the rest of our brands pursue excellence in innovation, jump over to the Johnson Outdoors’ Outdoor Adventure Blog. To learn more about Old Town and their impressive line of fishing kayaks, rec kayaks and legendary canoes, visit oldtowncanoe.com.