Consumer ProductsFood 3D Printing

GISE CAFFÈ and Formlabs produce energy-saving coffee machine

Combining traditional design and production techniques with 3D printing to develop the company's patented closed system

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GISE CAFFÈ was founded in 2021 by a team with over 40 years of experience in the coffee sector. The company created a patented closed system that produces coffee of superior quality – comparable to that made by a professional bar machine. After launching its first machine in 2022, the brand is now available in over 300 multi-brand stores and opened its first GISE CAFFÈ store in La Spezia at the end of 2023. Its 100% robust Ostro coffee has already won the discerning palates of Italy’s toughest judges, earning the Camaleonte ‘Product Award’ from the Guide of Coffee and Roasteries of Italy.

The GISE CAFFÈ patented closed system integrates a series of innovations developed over years of research. Its design focused on key points: component quality, ease of machine maintenance, and energy-saving capabilities – allowing for quality coffee without wasting energy.

GISE CAFFÈ and Formlabs produce energy-saving coffee machine - combining traditional design and production techniques with 3D printing.

To develop its innovative system, the GISE CAFFÈ team combined traditional design and production techniques with innovative technologies like 3D printing. This technology was used to test various modifications before applying them to injection molds – saving costs and reducing time. The team chose Formlabs’ solutions for their affordability, system scalability, high performance, and ease and speed of use. This provided a significant advantage for the technical office – saving time and allowing the immediate use of the 3D printer for designing the first market-released machine, the Aura, with support from SolidManufacturing, a company of the SolidWorld Group and a Formlabs reseller in Italy.

The innovative GISE Technology dispensing system ensures the coffee quality. The machine, composed of multiple internal components, is particularly complex and includes various mechanical components. Designing it required dozens of iterations to understand the functioning of each component, from levers to supports to pivots, and their interaction with other parts. To quickly obtain parts with shape variations as small as half a millimeter, almost all functional components of the machine were 3D printed using Formlabs’ SLS technology on the Fuse 1+ printer. Paired with a wide range of industrial-quality materials, it meets the challenges of functional prototyping and production – delivering high-performance prints in less than 24 hours.

GISE CAFFÈ also used the Formlabs SLA Form 3+ printer with various resins: Grey Resin for small aesthetically pleasing parts like plastic covers or caps, or moving parts not subjected to too much stress, and High Temp Resin for its transparency, to observe the internal behavior of the piece, particularly the disturbance created in the coffee inside the dispenser, and for its high-temperature resistance to print components that must withstand high pressure. Finally, Flexible 80A Resin was used to simulate rubber keyboards, covers, and other small seals.

GISE CAFFÈ and Formlabs produce energy-saving coffee machine - combining traditional design and production techniques with 3D printing.

“3D printing allows us to test each modification in advance on existing molds or precisely define a new component for which we want to create a new mold. Since creating or modifying injection molds typically requires investments of tens of thousands of euros, validating each component in advance results in significant savings in both time and cost,” said Tiziano Fantoni, CEO of GISE CAFFÈ. “The market we operate in moves very quickly; therefore, we are already working on other similar groups using different shaped capsules or different characteristics and new machines. 3D printing is now an integral part of our workflow.”

“Our printers and materials are designed to enable anyone to print anything, whether individual designers, large companies, or SMEs new to this technology and wanting to integrate it into their workflow. We are very pleased to see how they have contributed to the creation of a new coffee machine that combines Italian tradition with energy-saving, a passion for this beverage, and the desire for continuous innovation that unites our companies,” said Marco Zappia, Channel Sales Manager for Italy at Formlabs.

“As a Formlabs partner for Italy, we have always leveraged our many years of expertise in industrial 3D printing as our strength and added value to offer customers, helping them choose and use the most suitable solution for their needs. This was also the case for GISE CAFFÈ, allowing them to identify the ideal Formlabs 3D printer models for their production,” said Mirco Paltrinieri, Sales Manager of SolidManufacturing.

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