Introduction

Primary Manufacturing is an industrial 3D printing and rapid prototyping company located in Humboldt, South Dakota. Offering a variety of production methods and materials, Primary designs and produces plastic parts, prototypes, and models.

Primary uses two resin-based processes known as digital light production (DLP) and continuous liquid interface production (CLIP) as well as fused deposition modeling (FDM) and multi-jet fusion (MJF). The materials range from flexible to rigid and from soft to hard. Specialized material properties include biocompatibility, heat and flame resistance, and chemical resistance.

From toys to aerospace parts, medical devices to sports prototypes, Primary has served a variety of industries to provide the best designs and components. The company has produced parts for local businesses, major electronic companies, and an air taxi startup.

Company history

Primary Manufacturing was founded by Ladd McCluskey in December 2016.  Raising two sons, the McCluskeys always had a desktop 3D printer running at their house.  They made trinkets and models, but nothing which had a practical use—the parts were too brittle and took several hours, if not days to print.

Upon graduating college, their oldest son Sean introduced them to a new system of 3D production called Carbon DLS, a resin-based CLIP process.  Unlike their desktop printer, Carbon’s DLS system had a commercial application and the parts could be produced in just a few hours.  What was most impressive, however, was the isotropic strength, incredible material properties, and the production-level finish.

Additive manufacturing (AM) is a relatively new process compared to more conventional production methods like machining or injection molding.  Unlike traditional, subtractive processes, AM builds components by fusing together one layer at a time.  Because there’s no tooling, molds, or extensive setup, industrial 3D printing allows more efficient prototyping and design changes.

Using advanced additive technologies, parts are built from the ground up enabling engineers to create designs that would otherwise be impossible with traditional methods of production.  Industrial 3D printing has freed engineers of many design constraints; they can now create complex, intricate parts with reduced size and weight.  

With Ladd’s engineering and management background, he saw an amazing opportunity to implement an incredible technology. In founding Primary, his goal was to bring advanced additive production to his community and generate new, local manufacturing and engineering jobs in small town South Dakota. The hope was to create opportunities which would encourage the young people to stay in their hometowns rather than move to larger cities for well-paying jobs.

Primary started out with just three employees, but with a high demand for production, Ladd has grown the company to ten full-time employees.  The engineering positions have drawn many young people to Primary.  For example, Primary has had graduates from the South Dakota School of Mines, South Dakota State University, and Southeast Tech engineering programs. 

In addition to drawing young people to work at Primary, Ladd has also been able to provide jobs to other local residents who are looking for career changes later in life.  Half of the employees live locally in the small town of Humboldt and the other half reverse commute from larger residential areas like the city of Sioux Falls.

Though Primary has the best machines and materials in the industry, the most important key to Ladd’s success is his employees.  He values them and the culture above all else.  It is because of their dedication, hard work, and talent that Primary is able to provide the best parts and overall experience to the customer.

Partnering with Carbon

When he founded the company, Ladd decided to partner first with Carbon because they were the best in resin-based, digital light production.  Before installing the machines, Carbon wanted to make sure Primary was a viable company.  They would not deliver until there were enough viable parts orders. 

In March 2017, just a month after registering with the IRS and hiring his first three employees, Ladd received several production orders. Soon thereafter, Carbon came to Humboldt, South Dakota to install two M1 machines and announced that Primary had become one of just four production partners.

One of the first orders was from Soundz, a power sports audio company. Primary designed, prototyped, and manufactured their new tweeter housing in just one week.  Later in April 2017, Ladd won 2nd place in the Governor’s Giant Vision Business Award.

Expansion

Primary has continued to partner with Carbon and work closely with several other industry leaders including 3D Systems to bring the best machines and materials to their customers.

With an increased demand and a need for a variety of materials, Primary upgraded one of the Carbon machines, purchased two 3D Systems Figure 4s, and added two Ultimaker machines.

While the Figure 4 is another resin-based machine, it enabled Primary to offer additional materials to their customers.  The Ultimaker machine gave customers the opportunity to use a FDM process, a more cost-effective method of production with a variety of material options.

Just as important to Primary’s growth is optimizing efficiency in both design and post-processing. Ladd has continued to invest in equipment and technologies which optimize time and minimize material waste. Primary has acquired equipment to expedite both design and post-production processes including a 3D scanner and new cleaning machines. 

Primary continues to expand materials and services offered. For example, most recently, Primary began offering a bridge-to-production service.  Known as “Bridge Manufacturing,” this growing niche of the industry uses rapid prototyping with 3D printing to test products in the market or run presales before transitioning to mass production with conventional methods. 

Ladd continues to explore additional opportunities for expansion and hopes to bring new processes, materials, and services to his customers soon!