UL Compliance
Electrical component certification for safety and performance
Energy & Clean Tech SolutionsView All Industries
Engineering the Future of Energywith Advanced Manufacturing
Forge Labs supports clean tech manufacturers with fast-turn 3D printed parts for battery enclosures, hydrogen fuel cell hardware, thermal-management manifolds, mounting systems, and production tooling. We build durable components that help energy teams validate performance and move hardware toward deployment.
Prototype Lead Time
1-5 Days
Energy-Grade Materials
15+
Temperature Resistance
200°C+
Cost Reduction vs Machining
75%
Energy & Clean Tech Overview
Manufacturing for Energy Innovation
Whether you are advancing hydrogen systems, EV power electronics, battery pack hardware, or renewable-energy infrastructure, Forge Labs helps shorten the path from prototype to validated hardware. Our additive manufacturing workflows are well suited to thermal housings, flow-critical parts, electrical enclosures, and test fixtures that need to survive demanding operating conditions.
Where additive creates leverage
Built for faster energy & clean tech decisions
Forge Labs helps teams move from design validation to production-ready parts without waiting on tooling lead times. Consolidated assemblies, lighter parts, and faster revisions give engineering teams more control over schedule, cost, and performance.
Key manufacturing benefits
- Accelerate development timelines and compress design cycles, enabling faster innovation and reduced time-to-market.
- Create complex thermal management systems impossible with traditional manufacturing through advanced additive manufacturing solutions tailored for energy & clean tech applications.
- Eliminate expensive tooling requirements, reducing upfront investments and enabling economical low-volume production.
- Enable lightweight designs for improved energy efficiency through advanced additive manufacturing solutions tailored for energy & clean tech applications.
- Support aggressive development timelines in the renewable energy sector through advanced additive manufacturing solutions tailored for energy & clean tech applications.
- Manufacture custom brackets and housings for field installations through advanced additive manufacturing solutions tailored for energy & clean tech applications.
Quality and compliance
Validation-ready builds for demanding energy applications
Energy hardware often combines thermal, electrical, and environmental constraints. We support that with material documentation, inspection, and validation-ready builds for battery, fuel cell, and power-system components.
Environmental Testing
IP rating validation for outdoor and harsh environment applications
Material Certifications
Documented material properties for energy-critical applications
Thermal Validation
Performance testing for high-temperature energy applications
Manufacturing Capabilities
Capabilities Engineered for Energy & Clean Tech
From concept models to production-intent hardware, each workflow is tuned for the precision, repeatability, and engineering confidence that energy & clean tech teams demand. Our capabilities span rapid prototyping with sub-millimeter accuracy, complex geometry optimization for weight reduction, and low-volume production with full material traceability — giving engineering teams the speed to iterate faster and the data to qualify parts with confidence.
EV & Battery System Components
Enclosures, trays, thermal interfaces, and cable management systems—printed in durable, temperature-tolerant materials for rapid validation and testing. Accelerate electric vehicle development with specialized components designed for next-generation energy storage.
Lead time
1-3 days
Temperature resistance
up to 200°C
Insight 3
Custom thermal barriers
Insight 4
Integrated cable management
Relevant technologies
Selective Laser Sintering (SLS)/Fused Deposition Modeling (FDM)/Direct Metal Laser Sintering (DMLS)/Stereolithography (SLA)
Material options
EV & Battery System Components
Fuel Cell & Hydrogen Systems
Mounting hardware, airflow components, and internal assemblies with complex internal channels or custom geometries for hydrogen applications. Support the hydrogen economy with precision-manufactured components.
Insight 1
Complex internal geometries
Insight 2
Pressure-rated components
Insight 3
Corrosion-resistant materials
Insight 4
Custom gas manifolds
Relevant technologies
Selective Laser Sintering (SLS)/Multi-Jet Fusion (MJF)/Direct Metal Laser Sintering (DMLS)/Fused Deposition Modeling (FDM)
Material options
Fuel Cell & Hydrogen Systems
Solar & Renewable Infrastructure
Mounting brackets, connectors, housings, and test fixtures printed with high-strength polymers for field-ready durability and weather resistance. Enable rapid deployment of renewable energy systems.
Insight 1
UV-stable materials
Insight 2
Weather-resistant designs
Insight 3
Custom mounting solutions
Insight 4
Field-proven durability
Relevant technologies
Selective Laser Sintering (SLS)/Fused Deposition Modeling (FDM)/Direct Metal Laser Sintering (DMLS)/Stereolithography (SLA)
Material options
Solar & Renewable Infrastructure
Power Electronics & Grid Components
Custom housings, heat sinks, and electrical components for grid-scale energy storage, inverters, and power distribution systems. Support the modernization of electrical infrastructure with advanced manufacturing.
Insight 1
EMI/RFI shielding capability
Insight 2
Thermal management integration
Insight 3
Electrical isolation properties
Insight 4
Grid-scale applications
Relevant technologies
Selective Laser Sintering (SLS)/Fused Deposition Modeling (FDM)/Direct Metal Laser Sintering (DMLS)/Stereolithography (SLA)
Material options
Power Electronics & Grid Components
Energy Storage Solutions
Specialized components for battery systems, capacitor banks, and energy storage infrastructure requiring precise thermal and electrical properties. Enable next-generation energy storage with custom-designed components.
Insight 1
Thermal runaway protection
Insight 2
Electrical isolation
Insight 3
Fire-retardant materials
Insight 4
Modular system designs
Relevant technologies
Selective Laser Sintering (SLS)/Fused Deposition Modeling (FDM)/Direct Metal Laser Sintering (DMLS)/Stereolithography (SLA)
Material options
Energy Storage Solutions
Production Tooling & Assembly Aids
Custom jigs, alignment fixtures, and production aids tailored for small batch manufacturing or legacy system support in energy applications. Streamline energy component assembly with specialized tooling.
Insight 1
Custom assembly fixtures
Insight 2
Quality control gauges
Insight 3
Installation tooling
Insight 4
Legacy system support
Relevant technologies
Selective Laser Sintering (SLS)/Multi-Jet Fusion (MJF)/Direct Metal Laser Sintering (DMLS)/Fused Deposition Modeling (FDM)
Material options
Production Tooling & Assembly Aids
EV & Battery System Components
Case Studies
Clean Tech Manufacturing Outcomes
Representative work in thermal management, battery hardware, and renewable-energy component development where testing speed is critical.
Case Study
EV Battery Thermal Management
Rapidly prototyped battery-pack cooling manifolds with complex internal channels so the engineering team could evaluate thermal performance, packaging, and manufacturability without waiting for machined tooling.
Key outcomes
60% faster development cycles
Complex internal cooling channels
Validated thermal performance
Production-ready prototypes
Material Library
Energy & Clean Tech-Grade Materials
Qualified materials selected for performance, certification requirements, and repeatable production in energy & clean tech environments.
SLS
Nylon PA12
Energy & Clean Tech grade
Chemical resistant polymer
- Sustainable manufacturing
- High-performance properties
- Recyclable material
View Material Details
SLS
Glass Filled Nylon
Energy & Clean Tech grade
Lightweight structural components
- Reduced material usage
- High strength-to-weight ratio
- Sustainable composite
View Material Details
SLS
Accura ClearVue
Energy & Clean Tech grade
Transparent optical components
- UV-stable formulation
- Clean manufacturing process
- High detail resolution
View Material Details
FDM
ULTEM 1010
Energy & Clean Tech grade
High-temperature performance
- Chemical resistance
- Long-term durability
- Environmental stability
View Material Details
SLS
TPU 88A
Energy & Clean Tech grade
Flexible seals and gaskets
- Chemical resistance
- Long-term elasticity
- Environmental compliance
View Material Details
SLS
PC-ABS
Energy & Clean Tech grade
High impact resistance
- Temperature stability
- Chemical resistance
- Dimensional accuracy
View Material Details
DMLS
Aluminum 6061
Energy & Clean Tech grade
Lightweight metal components
- Corrosion resistance
- Recyclable material
- Sustainable manufacturing
View Material Details
Explore Our Complete Material Matrix
Compare certifications, mechanical properties, and application fit across our full portfolio before locking your production material stack.
Manufacturing Technologies
Proven Technologies for Energy & Clean Tech
Evaluate each process by geometry freedom, material options, and throughput so you can pick the right path from prototype to production.
Selective Laser Sintering (SLS)
Build Volume340 × 340 × 600 mm (13.4 × 13.4 × 23.6 in)
Layer Height60 - 120 microns
Materials4 available
No Support StructuresCost-Effective for Complex Parts+4 more
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Fused Deposition Modeling (FDM)
Build Volume914 × 609 × 914 mm (36" × 24" × 36")
Layer Height127 - 330 microns
Materials7 available
Large-Format PrintingCost-Effective Manufacturing+5 more
Learn More
Direct Metal Laser Sintering (DMLS)
Build Volume380 × 284 × 380 mm (15 × 11.2 × 15 in)
Layer Height0.02 - 0.06 mm
Materials6 available
Fully Dense Metal PartsComplex Geometries+5 more
Learn More
Stereolithography (SLA)
Build Volume1500 × 750 × 550 mm (59 × 29.5 × 21.7 in)
Layer Height0.025 - 0.150 mm
Materials5 available
Highest DetailSmooth Finish+2 more
Learn More
Need help selecting the best process?
Our application engineers can map your requirements to the right technology, material, and finishing workflow before you commit to a build.
Start a quote
Ready to Transform Your Energy & Clean Tech Manufacturing?
Upload your CAD files for an instant quote or speak with our application engineers about your specific requirements.
- Instant pricing with automated manufacturability analysis
- Production workflows built for repeatable quality
- Engineering support from prototype to production
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STL, STEP, OBJ, 3MF supported
Instant pricing and manufacturability feedback
- 6
- Manufacturing technologies
- 50+
- Engineering materials
- 1-500+
- Part quantities