I-CUP bike race medals — Red Rock Events LLC
Overview
Red Rock Events LLC required 1000+ custom medals for the I-CUP mountain bike series held throughout the Western United States. Merit3D used SLA 3D printing from Photocentric Magna machines to produce these high-quality, hefty medals with integrated moving parts in our Price, Utah facility without any initial tooling hurdle.
The Challenge
Most medals used for bike races are identical, generic products that lack weight and character. Red Rock Events wanted a unique, hefty award that would stand out to competitors while remaining within a specific budget. Traditional manufacturing would have required committing to the mold costs, which creates a production launch liability for a custom design. The customer needed a way to produce thousands of parts that included complex geometry without the high entry cost of dedicated hardware.
The Solution
Merit3D used SLA 3D printing to manufacture 1,000+ medals using Photocentric DL 110 resin. By using additive manufacturing, we bypassed any molds needed to create these. Our team designed the medal with an integrated rotating intersection that turns freely, a feature that was printed in-place. This allowed for a complex, multi-part feel without any extra assembly steps. After printing, the medals were finished with Cerakote to ensure scratch resistance and color options. We achieved a 2-3 week lead time from the approved design to the first production parts.
The Results
Merit3D successfully produced 9,000+ medals that provided a level of detail and functionality impossible with traditional casting or molding at this price point. By sinking no capital into dedicated hardware, the customer avoided fixed cost exposure while receiving a superior product. These parts were manufactured entirely in the USA at our Carbon County facility. We proved that the same principles used to work a coal seam or fix a tractor—precision and hard work—now allow us to produce 40,000+ parts per week for customers across the country.
Technical Specs
| Specs | Value |
|---|---|
| Process | SLA |
| Material | Photocentric DL 110 |
| Part Quantity | 1000+ |
| Lead Time | 2-3 weeks |
| Surface Finish | Cerakoted |
| Tooling Cost | $0 |
Why Merit3D
Merit3D is located in Price, Utah, a region historically dependent on coal mining that is now a leader in production-ready additive manufacturing. We provide a digital inventory that eliminates warehouse costs and allows local businesses to scale from a single part to many 1,000+ parts per week with no minimum order quantity.
