[CASE STUDY] Revolutionizing Instrument Design with MJF Additive Manufacturing: The WARBL Mouthpiece

Using Multi-Jet Fusion (MJF) for Innovations in Creating Unique Consumer Products

When a seasoned creator and instrument maker set out to create the WARBL—a MIDI wind controller that mimics the experience of playing a flute or whistle with advanced tech built in—he knew the design would require precision engineering.

With over 20 years of experience building stringed instruments and a decade of crafting electronic ones, creator Andrew Mowry was no stranger to solving complex design challenges. However, the WARBL’s compact form factor presented a unique problem: its mouthpiece needed to incorporate intricate internal passages that couldn’t be achieved with traditional manufacturing methods like injection molding.

Unique Design Challenges

The mouthpiece wasn’t just another component; it was the cornerstone of the instrument’s design. Its success would determine whether the WARBL could function as intended, and the stakes were high.

Andrew had already explored several additive manufacturing technologies, including SLS, SLA, and Carbon DLS, but none delivered the combination of surface quality, durability, and biocompatibility he needed.

Some prototypes had rough textures; others lacked the necessary strength or consistency. This design is nearly impossible to machine or injection mold so it was imperative to find a solution that worked. 

Even after narrowing down the options to a superior 3D Printing technology– Multi Jet Fusion (MJF), it was challenging to find a manufacturer capable of delivering consistent, high-quality results. Especially at critical post-processing step, the finishing often fell short, leaving parts that didn’t meet his standards.

Finding a Quality Solution

Frustrated but determined, this creator turned to SICAM, another rapid prototyping and additive manufacturing company discovered through a Google search, and was immediately struck by their personalized approach. Unlike larger manufacturers, SICAM didn’t treat him like just another order number. Pete, a member of the SICAM team, reached out directly after Andrew submitted a quote request, setting the stage for a collaborative partnership.

“Our company was built for engineers by engineers. We’re glad to work directly with our customers and build their projects with the highest quality and precision.” – Pete Sayki

What stood out most was SICAM’s willingness to fine-tune their processes to meet Andrew’s specific needs.

Powder Removal Problem

The design led to channels where powder from the print process could sometimes become trapped, but SICAM was able to make adjustments in the post-process to address this more effectively. He acknowledged that his design pushed the limits of HP's recommended passage dimensions, which contributed to cleaning challenges.

The Finishing Process

Vaporsmooth in particular, had been a pain point with previous manufacturers, but SICAM’s team worked closely with him to ensure a polished, professional finish. The VAPORSMOOTH post-processing service not only improved the mouthpiece’s appearance and enhanced its water resistance and durability.

The result was a part that looked and felt like it had been injection-molded—a crucial factor for a product intended for consumer use.

The collaboration didn’t just solve the mouthpiece problem; it transformed the production process for the WARBL.

SICAM’s 48-72 hour turnaround time meant Andrew could rely on consistent, timely deliveries, even with over 100 unique parts in his device.

Attention to Detail

"The pricing was competitive, but the value went far beyond cost. The quality of the mouthpieces exceeded what I received from other manufacturers, and the personalized support made all the difference," said Andrew.

Reflecting on the impact of SICAM’s solutions, this creator described SICAM as a “game-changer.” Without the 3D-printed mouthpiece, the WARBL wouldn’t exist. Thanks to SICAM, he has been able to produce and sell thousands of devices, each equipped with a mouthpiece that meets his exacting standards.

The collaboration has been so successful that he’s already planning future projects with SICAM, including a second optional mouthpiece design and additional accessories for the WARBL.

When asked if he would recommend SICAM, this creator didn’t hesitate. “I’ve recommended SICAM in the past because they care about even low-capacity clients like me, which is rare,” he said. “Their personalized interaction and attention to detail have been invaluable.”

Andrew appreciated SICAM's collaborative approach, noting the design feedback, and hands-on support to address challenges like powder removal.

This partnership is a testament to what’s possible when innovative technology meets a customer-first approach. SICAM’s expertise in additive manufacturing and commitment to quality didn’t just solve a problem; it enabled a vision.

For engineers, designers, and creators looking to bring ambitious projects to life, SICAM proves that precision manufacturing isn’t just about making parts—it’s about making possibilities real.