Case Study: Rapid Shell Manufacturing for Infrared Forehead Thermometers Using 3D Technology

The global COVID-19 pandemic significantly increased the demand for infrared forehead thermometers, essential tools in public health monitoring. However, rapid mass production has been challenged by disrupted supply chains and component shortages—particularly in the manufacturing of plastic housings for these devices.

To address this bottleneck, manufacturers turned to 3D scanning and 3D printing as a fast, cost-effective solution for producing the plastic casings required in thermometer assembly.

Challenge: Supply Chain Delays in Housing Production

Producing an infrared thermometer requires numerous components:
ABS plastic housing
 PCB circuit boards
 ICs, resistors, and capacitors
 Infrared sensors
 LCDs, backlight units (BLUs)
 Battery cable clamps

Among these, the plastic shell—typically produced via injection molding—can cause delays due to mold development time and limited manufacturing capacity during crises.

Solution: Digital Manufacturing Workflow with SHINING 3D

To accelerate product development, a digital manufacturing solution was implemented, combining industrial-grade 3D scanning with resin-based 3D printing.

Step 1: 3D Scanning the Thermometer Housing

Using the SHINING 3D OptimScan 5M, engineers captured high-resolution 3D data of an existing forehead thermometer shell in just 15 minutes. The scanner delivers accurate detail capture, critical for reverse engineering and reproduction.

Step 2: Data Processing

The 3D scan was processed to clean the mesh, extract design features, and prepare the model for printing. Geometries were optimized for accuracy, ensuring proper fit and function with internal components.

Step 3: 3D Printing the Shell

The refined model was printed using the EP-A350 resin 3D printer.

Key Specifications:
 Print Time: Approx. 4 hours
 Accuracy: ±0.08 mm
 Scanning Speed: 6–10 m/s
The result was a high-quality, functional shell suitable for prototype testing or small-batch production.

Results & Benefits

Rapid Turnaround: Full shell produced in under 5 hours
Cost Savings: No need for expensive or time-consuming mold creation
High Precision: Consistent output with excellent surface finish
Agility: On-demand small batch production for urgent supply needs

With this workflow, manufacturers were able to respond quickly to urgent demand and maintain continuity in thermometer production.

Conclusion: Winning the Race Against Time

This case study highlights how 3D digital technologies—from high-resolution scanning to precise additive manufacturing—can dramatically reduce lead times and enable agile, scalable production in emergency scenarios.

As global industries adapt to unforeseen challenges, digital solutions like this one offer a competitive edge in both speed and flexibility—essential in the fight against public health crises.