Real hardware prototyped with speed, intelligence, and affordability
dustin.burd 
Exploratory process for evaluating the limitations of copper filament by Virtual Foundry for fabricating hollow, thin walled components.
The thumbnail image was adjusted with Ai editing to improve lighting and give the studio lighting look. Any changes made to the original image have been judged to still be representative of the actual subject. If interested ask for the original images.
This buckle was designed by Dustin Burd before starting Lean Lines. An original part was 3D printed and post processed before being used as the master for making a silicone mold. Rigid and flexible thermoset urethane plastics were injected into the mold to make the picture part.
Images were adjusted with Ai editing to improve lighting and give the studio lighting look. Any changes made to the original image have been judged to still be representative of the actual subject. If interested ask for the original images.
Belay glasses designed by Dustin Burd before starting Lean Lines to evaluate the feasibility of using a silicone mold made with polished surfaces to cast clear urethane optical prisms with embedded mirrors. The image below represents an optical evaluation showing the redirected view through the cast prisms.
The thumbnail image was adjusted with Ai editing to improve lighting and give the studio lighting look. Any changes made to the original image have been judged to still be representative of the actual subject. If interested ask for the original images.
A purpose-built assembly integrating commercially available hardware, custom 3D-printed geometry and machined parts purpose built in hours, not weeks or days.
The thumbnail image were adjusted with Ai editing to improve lighting and give the studio lighting look. Any changes made to the original image have been judged to still be representative of the actual subject. If interested ask for the original images.
High‑resolution micro‑tubes produced through additive manufacturing, offering uniform geometry, crisp edges, and dependable performance for fluid paths, cable guides, and miniature assemblies.
The thumbnail image was adjusted with Ai editing to improve lighting and give the studio lighting look. Any changes made to the original image have been judged to still be representative of the actual subject. If interested ask for the original images.
Dustin Burd made this anatomical phantom as part of hi masters work at UNLV. The goal was to asses the effectiveness of a novel treatment for sleep apnea and validate force and pressure values computed numerically with computer simulations. The diagram shows the experimental design used to collect this data from the physical model.
This top‑down recording captures the mechanical behavior of the soft palate and posterior pharyngeal wall within a lifelike anatomical phantom. The video demonstrates how the upper airway narrows and collapses under negative pressure, supporting visualization of airflow obstruction dynamics
A customer came to Lean Lines with a broken and cloudy fuel gauge lens from a vintage car after a fruitless search for replacement parts. We made a 3D model replicating the lens then 3D printed and post processed it. During post processing, the outer edges were sanded to create a frosted look and the rest was polished for maximum clarity. The part was accepted despite the presence of a subtle line of bubbles that were cured into the resin. These bubbles only became visible after polishing and are more noticeable in the photos than in hand. We were able to eliminate bubbles in future prints using slower printing speeds and higher temperatures.
A quick demo of a novel ESP32‑powered Formula 1 tracker running on an E‑Ink display, styled with a Red Bull pit wall–inspired interface. This project shows live race data on a low‑power e‑paper screen with a clean F1‑themed layout.
Idea for project originated from the original work of mazzur888 as presented on a hackaday.com blog post.
Gituhub repository https://github.com/mazur888/F1-Info-display (Not affiliated with Red Bull Racing of F1).
The thumbnail image was styled with Ai editing. Any changes made to the F1 trackers look have been judged to still be representative of the actual subject. If interested ask for the original images.
This video shows an early prototype of an automated gate‑trimming machine designed to separate injection‑molded parts from the runner at the gate. The system uses a motor‑driven cam wheel to actuate a cutting die, with an integrated position sensor that tracks the cam’s rotation to ensure consistent timing during each trim cycle. The part tray includes positional sensors that detect when the tray is fully extended for cutting or retracted for part removal, allowing the machine to sequence operations safely and repeatably. A clear vinyl enclosure surrounds the mechanism, protecting the system from dust and debris while also serving as a physical barrier between the moving components and the operator. This prototype was fully functional and operated close to production acceptance levels, though it was not yet fully validated for final manufacturing use. It represents an initial design iteration focused on demonstrating the trimming concept, motion control, and safety features.
The thumbnail image was adjusted with Ai editing to improve lighting and give the studio lighting look. Any changes made to the original image have been judged to still be representative of the actual subject. If interested ask for the original images.