BJ Brugman (Agricultural Business 2012) moved back to Ames to build his business, Distynct, hoping to take advantage of the central Iowa agtech scene as well as access to resources and talent at Iowa State University. A recent project Brugman and his team at Distynct are a practical demonstration of what an entrepreneurial ecosystem can do for helping an early-stage business make progress.

In Distynct’s office in Building 7 of the ISU Research Park, there’s a cubicle with a steady noise. But it’s not someone on the phone or video conference or the key taps from a computer. Rather, two 3D printers sit side-by-side printing out blue cases.

3D printers making sensor containers for Distynct.

The blue cases being printed will contain sensors for feed bins in swine barns. The Distynct Connectivity Engine brings reliable, stand-alone internet to swine barns, transforming sensors into powerful smart alarms. Think Ring and other smart home devices, except for a swine barn.

“The feed bin monitor is a new product,” commented Brugman. “We went through a process of development that involved identification of which parts of the monitor we could build versus which parts we could buy from other businesses.”

Craig Blass (Agricultural and Biosystems Engineering 2016) picked up the story. “We needed a housing to mount the sensor to the feed bin. We looked at different alternative and though we would probably use injection molding.”

Injection molding is a manufacturing process used to produce parts by injecting molten material into a mold. It is commonly used for making plastic products, but it can also be used with other materials, including metals, glass, and elastomers.

“Mikayla Mooney (Global Resource Systems 2017) connected us to an injection molding company,” commented Blass. “We provided them with our preliminary design, and their estimate was that it would cost about $70 per unit to produce them, which seemed high.”

Enter Austin Rowe, an intern for Distynct who’s majoring in Agricultural and Biosystems Engineering. “I’ve got my own 3D printer at home, so I suggested we look at printing the housing. We already had the CAD design, so it was only a few more steps to get the point where we could print them.”

The Distynct engineering team began to explore the idea of making the housing using 3D printers. Next door in Building 7 is CIRAS (Center for Industrial Research and Service), part of the College of Engineering and the Office of Economic Development and Industry Relations (EDIR) at Iowa State University. Since 1963, CIRAS has partnered with Iowa companies and communities to help them prosper and grow.

“Our roles at CIRAS let us help businesses all over the state; it’s not too often that I get to help the person literally in the next room.”, said Jake Behrens (Technology System Management 2013), Project Manager for CIRAS. “Distynct was able to leverage resources at the Digital Manufacturing Lab, Powered by Alliant Energy, in Research Park Building #7 to determine if 3D printing was a viable option for their product. “The lab is here to help businesses de-risk technology adoption, which is exactly what we did here.”.

The result of these people working together today are two 3D printers in a cubicle in Distynct’s office, printing sensor housing units 24 hours a day, 7 days a week. “We can print 12 units per day,” said Blass. “That’s running them night and day. The gym is close to the office, so I stop to get a batch going in the morning before I go to the gym. Then I start it again late in the day, so it runs overnight. We’ve paid for the printers with the first 120 units we produced, so it’s a high return on investment project.”

Manufacturing in a cubicle? “You bet,” says Blass.

And an example of an entrepreneurial ecosystem in action.

Austin Rowe, Craig Blass, and BJ Brugman of Distynct.