Custom 3D printed tool holders

Where craftsmanship meets innovation: the revolution in custom 3D printed toolholders

For generations, the humble knife handle served primarily as a functional interface—a way to safely use a blade. While materials evolved from wood and bone to synthetics, customization remained limited. Additive manufacturing is a technological leap that enables craftsmen, chefs, collectors, and industrial users to completely reimagine handle design. Custom 3D printed toolholders represent more than just a trend; they are a paradigm shift in personalization, ergonomics and performance.

Why choose custom 3D printed tool holders?

The advantages are compelling and multifaceted:

1. Ultra-personalized ergonomics: Forget the generic "One size fits all." 3D printing allows handles to be carved precisely to the contours of the object your hand. Factors such as grip strength, finger length, hand shape and intended use can all be factored into the design. This greatly reduces fatigue, improves control, enhances comfort during extended use, and minimizes hand stress. It’s custom ergonomics at their finest.
2. Unprecedented Design Freedomningar: Traditional manufacturing imposes limitations—undercuts, internal structures, or complex geometries are often not possible. 3D printing unlocks these possibilities. Imagine a handle with integrated weight balancing chambers, an internal grid structure that reduces overall weight while Teatro maintains strength, contoured finger grooves that wouldn’t be possible to machine in a traditional way, or even integrated compartments. Aesthetic sophistication soars, allowing truly unique geometric patterns and textures to be born and become a reality in CAD software.
3. Material Innovation and Performance: Does the application require corrosion resistance? Extremely light? Excellent grip when wet? High temperature resistance? 3D printing offers unparalleled material versatility:

   • Metal (SLM/SLS): Stainless steel (316L, 17-4 PH), titanium (Ti6Al4V), aluminum alloy. Ideal for rugged kitchen knives, tactical tools, and industrial blades that require unparalleled strength, hygiene, and heat/chemical resistance.
   • Engineering polymers (SLS, MJF): Nylon (PA11, PA12), TPU. Offers lightweight durability, ergonomic flexibility (TPU), good impact resistance and textured grip. Ideal for EDC knives and specialty tools requiring shock absorption.
   • Composite materials: Printed with a carbon fiber or glass fiber reinforced polymer matrix using technologies such as Markforged, its strength-to-weight ratio exceeds that of aluminum.

4. Rapid prototyping and iteration: Traditionally, perfecting a handle design can be a long and expensive process of trial and error. With GreatLight’s 3D printing, design iteration becomes fast and cost-effective. Design-fail-learn-improve cycles happen quickly, allowing for improved ergonomics and aesthetics before going into final production.
5. Preserving Heritage Blades: An important niche application is repairing or upgrading prized heirloom knives with damaged or deteriorated handles. A custom handle created to fit perfectly breathes new life into an old-school blade, preserving its heritage with modern functionality.

Technology: Turning digital dreams into tactile reality

At GreatLight, we specialize in advanced Selective Laser Melting (SLM) Metal 3D printing – the cornerstone for producing strong, high-performance metal tool handles.

• Sustainability management process: A high-power laser selectively melts fine metal powder (layer by layer) precisely according to the 3D CAD model. This results in a fully dense, near-net-shape part with mechanical properties virtually indistinguishable from forged parts, which is critical for handles that withstand constant torque and impact.

In addition to metals, we also utilize:

• Selective Laser Sintering (SLS): Fused polymer powder, such as nylon, creates a durable plastic handle with less inherent stress than SLM metal.
• Multi-Jet Fusion (MJF): Offers faster polymer printing speeds and excellent surface quality/detail.
• Expert post-processing: Printing is just the beginning. Our one-stop service ensures your handle looks and feels the way you expected:

  • Metal handle: Precision CNC machining (optional for critical interfaces), meticulous support removal, sandblasting, hand polishing, barrel grinding, electropolishing, heat treatment, electroplating or PVD coating (DLC, TiN).
  • Polymer handle: Smoothing (vapor polishing/tumbling for SLS/MJF), staining, sealing.

Build your controller step by step with GreatLight

1. Vision and Consulting: Define your needs – primary use (chef’s knife, EDC, bushcraft), materials required, aesthetics, ergonomic priorities and budget. Share sketches or concept images. Our engineers guide you to find the best solution.
2. design: If you lack CAD skills, take advantage of our Design for Additive Manufacturing (DfAM) expertise. We translate your requirements into manufacturable 3D models that are optimized for your chosen process and incorporate ergonomic contours and functional features. For existing blades that require scale replacement, precise measurement/scanning ensures a perfect tang fit.
3. Material selection: Work with us to take advantage of our extensive metal and polymer capabilities to select the material that best suits your application needs.
4. Prototyping (optional): Test-fit plastic prototypes (SLS/MJF) to perfect ergonomics and dimensions before final metal printing.
5. print a & tidy: Your design is printed using the advanced technology of your choice. We carefully apply specified finishing processes to achieve perfect results.
6. Assembly and delivery: Handles are quality checked, securely packed and shipped. We can also advise on assembly methods if required