[Case Study] Creallo X Lanipet: Revolutionizing Pet Toys through 3D Printing and Injection Molding Synergy

Project Summary

Partner: Lanipet — A premium pet lifestyle brand
Objective: Realizing an adhesive-free, integrated structure for pet toys
Deliverables: 'Hodu-Ball' (Hard toy with an integrated internal ball) prototyping and mass production
Processes Applied: SLS 3D Printing (Integrated printing of internal shell + ball) & Injection Molding (Outer shell, PA11 FDA Grade)
Key Achievements:
- Achieved a complex, integrated internal structure without molds or adhesives
- Implemented eco-friendly design based on bio-based materials (PA11)
- Attained ultra-high precision with fusion gaps under 0.03mm
- Realized a 2-day turnaround for mass production (3,000 units), including dyeing, with SLS 3D Printing
- Ensured material safety and structural integrity through a strategic hybrid manufacturing approach (SLS 3D printing + injection molding)

Lanipet — A Brand Built by Manufacturing Experts

Lanipet was founded by experts with extensive experience in precision manufacturing and product development. Their journey began with a simple yet fundamental question:

Can we confidently recommend this product to our own pets?

Their first product, the 'Hodu-Ball,' is the definitive answer to that question. They focused on material over appearance, structural integrity over price, and above all, the manufacturing process itself. Creallo served as a total manufacturing partner, collaborating from the initial design phase through to mass production.

Lanipet prioritized material safety, structural integrity, and the manufacturing process itself, partnering with Creallo to manage the entire production journey—from initial design to mass manufacturing.

The Core Challenge — "A ball within a ball, without adhesives"

The design of the Hodu-Ball was clear but technically demanding. It required an integrated structure where a small ball rolls freely inside an internal shell—all without any adhesives or separate assembly processes.

This structure is nearly impossible to achieve with traditional injection molding, as splitting the mold for assembly inevitably requires chemical bonding or welding. For a product a dog bites every day, Lanipet refused to compromise on safety. To solve this, Creallo utilized SLS (Selective Laser Sintering) 3D Printing.

To realize an integrated structure where a small ball rolls freely inside an internal shell, Creallo utilized SLS 3D printing to achieve a seamless, single-process build.

SLS Technology: 3,000 Parts in 2 Days, Zero Assembly Required

SLS uses a laser to sinter powdered material layer by layer, allowing for the creation of complex internal geometries in a single process without the need for molds.

For the Hodu-Ball, the gap between the outer shell and the internal ball was precisely engineered so that both structures were formed simultaneously during a single print cycle—remaining independent without fusing. No assembly or glue is needed. Once the printing is finished, the ball is already perfectly nested inside the shell.

The PA12 Nylon used for this project is a high-strength material also found in drone frames and industrial robotics. Its exceptional wear and impact resistance ensures it survives the constant biting and impact typical of pet play. By bypassing the mold-making phase, Creallo completed the production and dyeing of 3,000 units in just 2 days, achieving a revolutionary reduction in lead time.

This structure was only possible because of SLS, and it was Creallo’s process engineering that brought it to life with such speed and precision. — Howard Jung, Director, Creallo

Using SLS 3D printing, Creallo completed the production of 3,000 internal shells and balls—including post-process dyeing—in less than 48 hours.

Hybrid Precision — Combining SLS with Injection Molding

While the internal structure was revolutionized by 3D printing, the outer shell—which comes into direct contact with the pet—was manufactured via injection molding to maximize safety and surface quality.

The material chosen, PA11 (FDA Grade), is a bio-based nylon derived from castor oil, containing no petroleum-based plastics. It is safe enough for medical devices and food-contact parts, ensuring no harmful substances are released even with repeated exposure to saliva and friction. This BPA-free design meets the highest safety standards for premium pet products.

Notably, the outer shell was also assembled using ultrasonic welding technology, allowing for a complete bond without the use of any chemical adhesives.

Uncompromising Quality Control

Before delivery, Creallo conducted rigorous inspections based on the following standards:

Zero scratches, oil marks, or surface defects on the outer shell.
Fusion gap of the outer shell maintained within 0.03mm (virtually invisible to the naked eye).
Pre-delivery assembly simulations to verify the fit and compatibility of each component.

Meeting two standards simultaneously—material safety and structural integrity—was the ultimate goal Creallo set for this project. — Howard Jung, Director, Creallo

The Road Ahead — Technology Completing Brand Philosophy

The Hodu-Ball is just the beginning. Lanipet believes that evidence-based choices in materials and manufacturing—rather than just trendy designs—build brand trust.

Creallo will continue to design the most optimal manufacturing paths for Lanipet’s future products, leveraging expertise in SLS, injection molding, CNC, and vacuum casting. Material safety, structural precision, and process efficiency—these three pillars will continue to support Lanipet’s brand positioning through superior technology.

Creallo: Your Trusted Precision Manufacturing Partner

Creallo provides the fastest and most accurate path from idea to product. From material selection to process optimization and quality control, Creallo shines brightest when the requirements are most demanding.

Experience the future of manufacturing with Creallo today.