CAD and 3D printing services
We use Autodesk Inventor 2025 to design solutions for customers wanting a renewable packaging solution.
A customer will send their part as an STP file or another type of CAD file to our CAD team. With our experience, we will create a suitable stillage to hold the customer’s part.
When designing the stillage, we think about how people will handle it. We also consider the cost of the product.
We look at transportation, like how many parts fit in a large lorry. We focus on how easy it is to make, and health and safety plays an important part too.
Finally, we aim to maximise storage space. This helps us create a product that meets our customers’ needs.
With over a decade of experience our design team can produce highly detailed drawings and 3D models to encapsulate the concept of a stillage.
We use Bambu Lab 3D printers for their high-quality printing and proven reliability by trusted professionals of the industry. Bambu Lab guarantee high speed performance with 20000 mm/s2 XY acceleration and dual auto bed levelling.
With these features we can produce high quality prototype mouldings in a short space of time. Helping us to test the concept before committing to volume production.
With the high performance Bambu Lab printers we can manufacture volume production fast and with the guarantee of quality polyurethane dunnage’s.
To find out more about what we can provide for your company, contact our design team below.
I've collaborated with Bluestar on several transport and storage solutions and the designs are exceptional. They optimise storage capacity while prioritising safety and product accessibility.
Trusted by companies all across the UK
Benefits of CAD and 3D printing services
Utilising a high level of customisation in the stillage design process has a variety of benefits for business operations:
Optimised functionality
We use Inventor to create virtual models that ensure our products perfectly accommodate various sizes, weights and shape of different components.
Improved safety
Inventor allows us to test the stresses and strains of our products and see how they perform under specific loads. Testing what weights our products can handle allows us to help our customers comply with a range of safety requirements and regulations from the offset, ensuring a rapid integration to business processes.
Efficient space
Euro Pallets or standard stillages will never utilise the space in a lorry or a warehouse to its full potential. CAD allows us to design stillages to precise measurements and configurations to maximise industrial spaces.
Benefits of using Autodesk Inventor
A myriad of benefits are on show to businesses which use 3D printing in their stillage design process:
Benefits of 3D printing
3D printing helps Bluestar in creating mouldings to work with for prototypes, this moulding technique can help to reduce the lead time of prototypes. This gives the utmost opportunity for functionality and fit optimisation before committing to final production.
Complexity simplified
3D Printing is not limited when manufacturing unique shapes and geometries. This allows our design team to have unlimited freedom in determining the best solutions for our customers.
Proof of concept
We use 3D printing to create the moulds for our stillage designs. This process enables us to design hollow structures, which helps reduce the weight of the final product while preserving its strength. By incorporating these lightweight, hollow features, we can enhance the overall efficiency and performance of the stillage.
Read our case studies
Here, we showcase how businesses from diverse industries have leveraged our services to achieve remarkable production results.
Focusing on maximising transportation space, we created a 3D model of a large articulated lorry loaded with our fully custom stillages.
This showed JCB how our products help to increase the amount of room in a lorry and how to help reduce the number of trips needed to carry the same amount of parts.
We work on providing cutting edge transport and storage solutions for automotive giants McLaren.
Taking advantage of our polyurethane moulding department, McLaren specify a variety of different measurements via thorough designs.
We take these and provide a fully bespoke output featuring the highest-quality materials and levels of production.
Lotus supplied us with CAD data for parts to be stored in one of our bespoke stillages. We designed a fully customised solution around the CAD drawings.
Taking this brief, we’ve completed thorough drawings and designed how the stillage will look.
With prototypes provided and approval secured, the bespoke stillages have revolutionised both transport and storage for Lotus.
Our Services
Polyurethane (PU) dunnage, on the other hand, is durable, reusable and highly customisable, meaning operations can be streamlined while costs are reduced.
We craft each bespoke stillage and post pallet with precision to accommodate your unique storage requirements. This removes wasted space and improves your storage.
When we refer to our stillages, what is the meaning of a Bluestar Stillage? Stillages are
strong storage and transport solutions.
