How Windsor Test Solutions Reduced Defects and Improved Lead Times with Obsidian™ PA6+CF
Using carbon fiber-reinforced filament to streamline EV battery testing and industrial fixtures
Company: Windsor Test Solutions
Industry: Electronic Manufacturing
Website: https://windsortestsolutions.com
Introduction
Windsor Test Solutions, based in Windsor, Ontario, was founded with a simple but ambitious goal: deliver high-performance electrical test adapters and industrial fixtures faster and more affordably than traditional manufacturing methods allow. Built by a team of engineers who understand the pressure of tight timelines and complex requirements, the company has leaned into 3D printing as the foundation of its product strategy. Instead of adapting their unique designs to fit within the traditional constraints of machining, they’ve committed to designing parts specifically for additive manufacturing, which opens the door for better geometry, improved performance, and faster results.
The Challenge
When it comes to engineering components for testing, every single project has its own unique demands. For the team at Windsor Test Solutions, this often means that they must build custom adapters and tools for electric vehicle battery testing and industrial assembly lines. It’s required that these parts fit perfectly, hold up to repeated use, and can be delivered on short notice. Time, performance, and precision are all critical factors and not even one can be ignored.
But when you rely on traditional machining, you run into trade-offs. Complex shapes are difficult and expensive to produce. Lead times stretch into weeks. And every time the design changes, which it often does, production stalls. It became clear that a faster, more flexible solution was needed, especially one that didn’t compromise on mechanical strength or part quality.
The Solution
Windsor turned to 3D printing to eliminate the bottlenecks that came with machining. However, not just any common 3D printing material would do. The parts they build need to be strong, stable, and reliable in tough environments. After testing several filaments, the team found what they were looking for in Obsidian PA6+CF from 3DXTECH.
Obsidian is a carbon fiber-reinforced nylon material built for demanding applications. Its PA6 copolymer base provides durability and toughness, while the added carbon fiber increases the material’s stiffness and print quality. For Windsor, this meant the ability to print complex parts that didn’t warp, didn’t crack, and stood up to real-world use.
The material’s chemical resistance was another plus, especially since many parts are exposed to oils, greases, and other contaminants during testing. And because Obsidian works well on a wide range of printers, the team didn’t need to retool or reconfigure their entire setup. It just worked.
What made the biggest difference, though, was the ability to design without compromise. With Obsidian, Windsor could prioritize part performance and usability instead of worrying whether a feature could be machined. The result was cleaner fitment, better function, and far fewer downstream issues.
The Results
Since switching to Obsidian for both prototyping and production, Windsor has seen a measurable improvement across the board. Design iterations that used to take weeks are now completed in just a few days. Costs have dropped significantly, particularly on low-volume assemblies that would otherwise require expensive machining.
The parts themselves have improved, too. By focusing on fit, function, and durability from the start, Windsor has been able to deliver tools and adapters that perform better in the field. Customers are seeing fewer failures and less downtime, which translates to real value on the production floor.
Beyond that, the workflow is simply smoother. Instead of reworking designs to fit the limitations of machining, Windsor’s team can move quickly from concept to part. That kind of agility isn’t just convenient; it’s a competitive advantage.
Why Obsidian PA6+CF?
Obsidian PA6+CF was developed to meet the needs of engineers and manufacturers who can’t afford to compromise on performance. It offers a rare combination of strength, printability, and dimensional accuracy, with excellent resistance to wear, moisture, and chemicals. For applications that require tight tolerances, long-term durability, and fast production, it’s an ideal fit.
Right now, Obsidian is available on sale for just $99 while supplies last! If you’re looking for a way to boost the performance and reliability of your own 3D printed parts, now’s a great time to try it.
To learn more about Windsor Test Solutions and how they’re using additive manufacturing to move faster and build smarter, visit windsortestsolutions.com. For more on Obsidian PA6+CF, check out the product page here.
