A Creator Pro Fuels Dreams: Flashforge 3D Printers Anchor One of America's Largest Print Farms
As the wave of digital transformation sweeps through manufacturing, 3D print farms are rapidly emerging as an innovative and efficient production model. But back in 2016, when the concept was still niche, American engineer Kason spotted 3D printing’s industrial potential and launched i-SOLIDS, a firm dedicated to production-focused 3D printing. Today, after eight years of steady growth, i-SOLIDS has become one of the largest and most influential 3D print farms in the U.S.
Currently, i-SOLIDS operates over 140 3D printers, spanning FDM 3d printers, resin 3d printers, and powder-based 3d printing technologies. Among them, rows of Flashforge Creator Pro printers, still running strong, stand out as iconic workhorses in the farm. Despite new equipment flooding the market, this "vintage" model remains the backbone of operations. Kason says the Creator Pro not only witnessed his company's growth but also marked the beginning of his strong partnership with Flashforge.
From a Home Workshop to 20,000 Sq. Ft. 3D Print Farms
"I began working with 3D printing in 2015. What started as a hobby centred on the best 3D printers for beginners soon presented potential for broader applications as technology advanced," Kason recalls. In 2016, he started i-SOLIDS as a side business. By late 2017, the fast 3d printer business had grown enough for him to move his printers from his home to a warehouse and make 3D printing his full-time career.
The Creator Pro he bought early on was essential. Its enclosed design was rare at the time, making it ideal for batch printing high-performance 3D printer filament materials like ABS filament and ASA filament. This capability allowed i-SOLIDS to enter the market with high-strength industrial parts.
In July 2025, to accommodate rapid expansion, i-SOLIDS moved to a new facility of approximately 20,000 square feet. The new facility can hold over 400 FDM 3D printers, with infrastructure designed for future growth.
3D Print Farm's Winning Formula: Stability, Efficiency, and Continuous Output
"We selected Flashforge because their printers are dependable and cost-effective, complemented by excellent customer service," Kason explains. The Creator Pro's decade-long availability and accessible replacement parts have significantly reduced maintenance costs, ensuring strong ROI.
To this day, 64 units of Creator Pro remain in service at i-SOLIDS, with many running non-stop for over six years. "While we've added newer, faster printers to our fleet, the Flashforge Creator Pro remains essential for its reliability, precision, and versatility," Kason says.
i-SOLIDS has evolved from handling small, individual orders for replacement parts, gifts, and prototypes to producing high-volume parts for businesses in the automotive, aerospace, healthcare, and consumer goods sectors. They manufacture electronic enclosures, brackets, mounts, and work with advanced materials like Ultem and PEEK for demanding industrial applications. The company's daily output exceeds 2,000 parts, depending on part complexity.
Lean Management: 3 People Run 140 Printers
Kason remembers that 2018 was a challenging first year, but the company generated around $180,000 in revenue at a 20% profit margin. Since then, they've experienced an average annual growth rate of 120%, consistently prioritizing profitability over sheer revenue, and expanding organically without external funding up through 2025. The new facility, which they moved into in July, can accommodate over 400 FDM 3D printers, with room for further expansion.
As the business grew, efficient management became a vital answer to how to start a 3d print farm. "As a sole proprietor, I adjusted quickly without formal communication or defined processes, but as the team expanded, these became essential," Kason says. "Major challenges are often political or environmental challenges, such as pandemics, conflicts, inflation, and supply chain disruptions—factors that are difficult to predict in business projections. However, each challenge also presents an opportunity. These situations have allowed us to demonstrate how adaptable additive manufacturing can be to changing economic conditions."
Now with 25–30 employees covering sales, quality control, post-production, and engineering, the FDM 3D printing farm needs just 3 dedicated staff for round-the-clock fleet management. "We believe manufacturing profitability relies on lean, efficient operations. Accordingly, we focus on well-defined, automated processes that deliver strong ROI. For instance, our custom software tracks production across all machines without paperwork."
(Parts Printed by i-SOLIDS)
Expanding into Multi-Color FDM 3D Printing: The Next Growth Frontier
While strengthening its mass production edge, i-SOLIDS is exploring new applications. Kason mentions that the team recently introduced the multicolor 3d printer Flashforge AD5X to expand its multi color 3d printing capabilities, now undergoing rigorous testing.
i-SOLIDS previously used powder-based technologies for full-color printing, but advances in multi color 3d printers have made it a more cost-effective alternative. Many of their customers don't need complex patterns; they just want to add a logo, a QR code, or a multi-colour label to their products, and the AD5X fits that perfectly.
Kason adds that the new facility's space, power, and network infrastructure position AD5X as a strategic asset for future scaling.
Advice for Entrepreneurs: Start Small, Think Long-Term
In Kason's view, 3D print farms are entering their golden age. He encourages entrepreneurs to start small, prioritize quality and customer feedback, build a strong and stable supply chain, and always assess their products or services from a customer's perspective.
Starting a large 3d printing services business is never easy. Many people only see the success result, but not the systematic processes and relentless daily execution behind it. To succeed, you must set clear expectations for yourself and your team, and take the long view.
Conclusion: Flashforge Powers a New Paradigm in Large-Scale Manufacturing
From a single Creator Pro that sparked a business to a print farm of hundreds of printers producing thousands of parts daily, i-SOLIDS has proven that large-scale 3D print farms are viable and sustainable. Throughout this journey, Flashforge's equipment—with its stability, durability, and cost efficiency—has been the underlying engine driving long-term growth.
This success story offers a blueprint for manufacturers worldwide exploring digital transformation, and it demonstrates how 3D printing can truly evolve from a prototyping tool into a true mass production powerhouse.
