Modern Industrial Factory_ Mechanical Engineer Wearing Virtual Reality Headset, Holding Co

CAD Design, Prototyping, 3D Modeling

From idea to ready to print

We turn concepts — whether sketched on a napkin or mapped out in detail—into accurate 3D models, prototypes & parts built for real-world use.

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Creative company professional digital engineer modeling 3D mesh while improving geometry.

PROTOTYPING

We turn your idea into a working prototype, optimized for real use. Perfect for testing, refining, and getting ready for 3D printing or production.

CAD DESIGN

We create production-ready CAD files for 3D printing, machining, or molding. Just tell us what the part needs to do—we’ll handle the design.

REPRESENTITIVE
MODELING

We produce accurate visual models that capture the form and intent of your design, space product or building. Ideal for demonstrations, presentations, or display pieces where precision and appearance both matter.

REVERSE
ENGINEERING

We recreate parts with precision—no CAD file needed. Ideal for broken, outdated, or hard-to-find parts needing redesign or replacement.

3D MODELING &
VISUALIZATION

We model your part or product so you can see it clearly before it’s made. Great for checking fit, function, or showing others what you’re building.

R&D

We act as an extension of your engineering team—developing concepts, solving complex challenges, and turning new ideas into tested, production-ready solutions.

OUR CAPABILITIES

CAD Design/
3D Modeling

3D Printing

R&D

Light Metal
Fabrication

Professional 3D scanner scanning an industrial object plastic molding placed on a turntabl

3D Scanning

Post Processing

VR Testing &
Collaboration

Assembly

OUR DESIGN TOOLS

We leverage a wide range of technologies in our design process including:

3D Scanning: Capture real-world objects and convert them into precise digital models;
Virtual Reality (VR) Testing: We test our designs in a fully immersive virtual environment.
CAD Design: Use of industry-leading CAD software to create detailed digital models.
3D Printing: We bring prototype designs to life quickly with FDM & SLA 3D printing.

Engineer examining a 3d printed prototype and comparing it with technical drawings..jpg

TRACEABILITY & DOCUMENT CONTROL

We prioritize transparency and reliability in providing rev-locked CAD files, material certs, build logs, inspection reports, and exportable compliance packs.

OUR PROCESS

CLIENT WORK

Through CAD design, 3D modeling, and iterative prototyping, we refine every concept until it’s functional, manufacturable, and ready to perform in the real world. Below are examples where that process came full circle—ideas transformed into precise, working solutions.

Cutter Guard for Industrial Dispensing Machine

Timelapse video capturing the creation of a custom cutter guard for Swisslog Healthcare's PillPick Machine

Brain & Peg Model

R&D, CAD, 3D Printing

Created for the Maryland Dept. of Health, these interactive models demonstrate how opioids bind to brain receptors—designed for use in public awareness campaigns.

Algae Photobioreactor

Contracted R&D, Prototyping & Production

Bauen Innovations was first retained by BrightWave, LLC to design and manufacture components for a custom algae photobioreactor system — our first major collaboration together. The project involved advanced CAD design, engineering, and production coordination to deliver 340 bioreactors for Northumbrian Water Company, laying the groundwork for our ongoing partnership.

CAD design and prototyping services in Baltimore, Maryland Home Page.jpg

Ignition Turner

R&D, CAD, Prototyping, 3D Printing

Developed a permanent keyless ignition system for 2018 Dodge Caravans. Built for Ports America Chesapeake, part of Ports America—the largest port operator in Amereica This is an ongoing project, with turners ordered quarterly for their fleet.

Lightpost Covers

R&D, CAD, Prototyping, 3D Printing

Recreated legacy light post covers no longer in production for Lighting Maintenance Inc. Final units are now in active use across their properties.

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Irish Bagpipe Key Covers

R&D, CAD, 3D Printing

Custom key covers designed and printed for an Irish bagpipe set, tailored to the client’s instrument and play style.

Custom Work Van

Branding

R&D, CAD, 3D Printing

This project brought together many discipline we specialize in—research, design, prototyping, fabrication, and production—to create a custom rocket flame for Beltway HVAC’s fleet rebrand. The result: a striking, one-of-a-kind accessory that turns their vehicles into bold, rolling statements.

CT Scan Head Positoner

Contracted R&D, Prototyping & Production

Engineered to precision for an inventor, this Patented CT Scan Head Positioner features optimized gear ratios for accurate motion control. A testament to Bauen’s expertise in complex mechanical design.

Scale Model

R&D, Prototyping, CAD, 3D Printing, Model Making

Designed and built for a bridge construction bid from a large civil contractor in DC

3D Scanning Library

Explore real-world examples of precision 3D scans, point clouds, and surface reconstructions performed by our team.

Project Media Library

Explore time-lapses, recordings, and real project footage that capture our work in progress — from design iterations to final production.

'Flame' for HVAC work vans

Hands of an engineer measures a metal part with a digital vernier caliper against the back

FREQUENTLY ASKED QUESTIONS

CAD Design, Prototyping & 3D Modeling

Short answer: You get the final, manufacturable files and full rights to use them in your business. Bauen retains the original working/source files unless a separate source-file buyout is agreed in writing.

What you receive (standard delivery):

Final production files in .STL and .STEP format
Unlimited commercial use within your own business and work (manufacturing, printing, referencing in future work)
Archival of your final files in our system for reference and support

What’s not included (without buyout):

Editable working/source files (e.g., Fusion 360 archives, SolidWorks native files)
Internal development data, parametric history, or proprietary methods
Transfer of Bauen’s original working files or project setup

Definitions (so we’re crystal clear):

Possession = you have the final file and can use it fully for your purposes.
Ownership of working files = control of the editable, parametric source that lets someone rebuild or repurpose the design. By default, Bauen retains ownership of the working/source files.

We design to tight dimensional tolerances and verify them before anything is printed.

Modeling & exports: We keep CAD in millimeters, use precise kernel accuracy, export STEP for parametric fidelity, and generate STL with fine mesh controls (small chordal error and angular deviation) so the geometry you approve is the geometry we build.
Fit & clearance standards: We apply a printed-parts clearance table (e.g., FDM typical press-fit: −0.1 to −0.2 mm; slip fit: +0.2 to +0.4 mm. Resin typical press-fit: −0.05 to −0.1 mm; slip fit: +0.1 to +0.25 mm) and run interference/clearance checks on every mating feature.
Process targets (typical):
- FDM: ±0.10–0.20 mm or ±0.2% (whichever is greater) on small features.
- Resin (SLA/DLP): ±0.05–0.10 mm on small features. Actual callouts vary by part size, orientation, and material; we state them on drawings.
Assembly review: We run tolerance stack-ups and motion checks in CAD so parts assemble without forcing or sanding.

We keep revisions simple and trackable. Here’s the step-by-step:

1) First draft (V0) We build the first model from your requirements and send a review pack: pictures or a view link, plus a short note on choices we made.	5) New version (V1, V2, …) You get a new pack with: Before/after pictures side-by-side A short list of what changed Any open questions we need you to decide
2) You mark changes Tell us what to change—write on the pictures or list bullets. Keep all feedback in one place.	6) Repeat until it’s right We loop steps 2–5 until the agreed scope is met.
3) We update the model We make the edits and check three things before we send it back: Key sizes match your numbers. Parts that touch each other have just enough space to fit after printing. Nothing collides when parts move or assemble.	7) Lock for production When you approve, we “freeze” the design so the shop only uses the correct files. We deliver: STEP and STL for manufacturing Simple print notes (material, orientation, any build tips) Updated pictures for your records
4) Quick reality check (when needed) If a fit is critical, we do a fast draft print of the tricky area to confirm holes, snaps, or slots.

What’s a normal revision? Small adjustments to sizes, hole diameters, wall thickness, rounded edges, label/text, or simple looks—without changing how the part works.

CAD Design, Prototyping, 3D Modeling

From idea to ready to print

Explore this Page

PROTOTYPING

CAD DESIGN

REPRESENTITIVE
MODELING

REVERSE
ENGINEERING

3D MODELING &
VISUALIZATION

R&D

OUR CAPABILITIES

OUR DESIGN TOOLS

TRACEABILITY & DOCUMENT CONTROL

OUR PROCESS

CLIENT WORK

FREQUENTLY ASKED QUESTIONS

Will I own the design file or do I have to pay extra?

How do you ensure the accuracy and precision of CAD models in complex assemblies?

How do you handle revisions in CAD design during the prototyping process?

CAD Design, Prototyping, 3D Modeling

From idea to ready to print

Explore this Page

PROTOTYPING

CAD DESIGN

REPRESENTITIVE MODELING

REVERSE ENGINEERING

3D MODELING & VISUALIZATION

R&D

OUR CAPABILITIES

OUR DESIGN TOOLS

TRACEABILITY & DOCUMENT CONTROL

OUR PROCESS

CLIENT WORK

FREQUENTLY ASKED QUESTIONS

Will I own the design file or do I have to pay extra?

How do you ensure the accuracy and precision of CAD models in complex assemblies?

How do you handle revisions in CAD design during the prototyping process?

REPRESENTITIVE
MODELING

REVERSE
ENGINEERING

3D MODELING &
VISUALIZATION