Skip to content 
When it comes to rapid prototyping and low-volume automotive manufacturing, few companies match the integration and scale of 3-Dimensional Services Group. Founded by Douglas Peterson in 1992, the company has expanded to over half a million square feet across Southeast Michigan—serving OEMs and Tier 1 suppliers with everything from precision seating structures to aerospace-grade aluminum milling.
Sandy Munro recently toured 3-Dimensional Services’ facilities in Rochester Hills and Lapeer. During the visit, he uncovered how vertical integration drives efficiency. The company combines lean design principles with advanced equipment. As a result, they can turn complex CAD designs into working parts in as little as eight weeks.
From CAD to Complete: One-Stop Prototyping
At the heart of 3-Dimensional’s appeal is its ability to go from CAD file to finished product entirely in-house. Whether it’s CNC cutting, stamping, robotic welding, or injection molding, the company eliminates typical outsourcing delays. During the tour, a 1,200-part seating system—completed in just eight weeks—showcased this vertical model. Every component, down to the custom fasteners and spring wires, was manufactured internally, underscoring their control over timelines and quality.
This capability isn’t just theoretical. Real-world applications include production-ready seating assemblies for vehicles already in market, each incorporating advanced high-strength steels and laser-welded components. With materials like DP980, forming complexity is high, requiring robust tooling strategies and multiple operations such as curling, restriking, and welding. Yet 3-Dimensional handles it all with precision and speed.
Bridging the Gap to Production
Many automakers struggle to meet compressed product launch schedules. That’s where 3-Dimensional’s “bridge production” shines. When OEMs face delays in tooling readiness, this facility steps in. For instance, a simple third-row aluminum back panel initially required a one-month supply stopgap. It turned into a nine-month engagement, producing over 100,000 parts with full quality validation.
Each part passes through attribute fixtures, ensuring compliance without relying solely on traditional inspection. These processes mirror full-scale production in amperage, weld sequencing, and material handling—so production vendors receive a validated and consistent design process.
Expanding Beyond Automotive: Lawn, Snow, Aerospace
While known for automotive work, 3-Dimensional also produces components for snowblowers, lawn mowers, and aerospace applications. Snowblower augers and lawnmower decks—some with deep-draw stampings and robotic MIG welds—demonstrate their flexibility across industries.
Their aerospace capabilities are equally advanced. New high-speed horizontal mills, like the 150-horsepower, 30,000 RPM Stagg Eco Speed 1540, remove aluminum at astonishing rates—up to a 55-gallon drum of chips per minute. With dual pallets and 18-hour unattended run times, these machines rival those at Boeing or Airbus, making 3-Dimensional a key supplier in high-precision markets.
Toolmaking and EDM: Legacy Meets Innovation
In tool and die, 3-Dimensional maintains a balance between old-school craftsmanship and high-tech efficiency. Their cell manufacturing system assigns each mold maker a dedicated work zone, complete with manual Bridgeports and access to CAD stations. This structure promotes mentorship and training of the next generation of mold makers.
On the digital front, their EDM department is powered by robotic tool changers and graphite electrodes with RFID tagging. This setup allows electrodes to be loaded, tracked, and cycled automatically, significantly boosting uptime. Even intricate features like sub-millimeter ribs are machined using diamond-coated tools and burned via EDM for unmatched accuracy.
Injection Molding at Scale
The Rochester Hills facility features 26 injection molding machines ranging from 30 to 1,500 tons. This enables the production of everything from tiny interior clips to large door panels. Their emphasis on quick-change mold bases and pre-stocked blocks means they can start a new job within minutes—not days—of receiving the green light.
This agility ensures they remain competitive in both prototyping and bridge production. Coupled with their in-house tool design and mold building, 3-Dimensional keeps costs and timelines tightly controlled.
Advanced Laser and Stamping Capabilities
Another standout is their Trumpf TruStore laser cutting and storage system. With twin towers and butterfly configurations, the 12kW 2D lasers run continuously thanks to automated material feeding. These are supported by 25 five-axis Trumpf lasers, among the most advanced available, enabling tight-tolerance, multi-angle cuts on complex parts.
Stamping remains a core strength, with 127 presses ranging from 20 to 5,000 tons—including capacity for tubular hydroforming. From seat backs to full chassis components, their ability to form, pierce, weld, and assemble makes them a one-stop shop at any stage of product development.
Robotic Welding and Smart Fixtures
For welding, 3-Dimensional runs 47 robotic MIG stations, 20 spot welders, and 6 laser weld cells. Smart fixture design, often using aluminum for heat dissipation, ensures consistent and repeatable welds even at low volumes. With trunnion-mounted fixtures and multi-axis access, robots can avoid vertical welds (typically less reliable) and focus on achieving optimal geometry and strength.
One seat structure program alone involved 150 sets, with plans for an additional 150 after a design revision. This kind of agility is rare in prototyping and confirms their readiness for low-volume EV and specialty vehicle builds.
Lean Design Meets Massive Horsepower
Ultimately, what sets 3-Dimensional apart is their horsepower—both in equipment and in engineering mindset. With over 75 CNC machines, 100+ presses, and dozens of weld cells and lasers, the company operates like a traditional OEM on steroids. Yet their culture prioritizes lean manufacturing, speed, and iteration.
This mix of scale and focus allows them to serve niche EV builders, mainstream automakers, aerospace clients, and beyond with unmatched responsiveness.
Final Takeaways: The Munro Verdict
Sandy Munro’s final assessment is telling. Despite touring countless facilities globally, he calls 3-Dimensional’s speed, integration, and capability “totally amazing.” The fact that they can deliver fully functional assemblies in six to eight weeks—and full-scale bridge production in ten to twelve—makes them invaluable to fast-moving, innovation-driven customers.
Their success lies not just in equipment but in a culture of accountability, precision, and relentless problem-solving. For OEMs, startups, or suppliers looking to accelerate development cycles without compromising on quality, 3-Dimensional Services Group delivers unmatched value.
Want more teardown tours and rapid-manufacturing insights?
Subscribe to Munro Live or explore our latest breakdowns and EV analysis at Munro & Associates. Stay ahead with the industry’s most trusted name in manufacturing intelligence.