How a HEXXI Is Made: From 3D Print to Finished Display

When you see a finished HEXXI on the wall, it can be easy to focus on the final result.

The hexagonal frame.

The artwork.

The display platform.

The finished theme.

But every HEXXI goes through several steps before it is ready to hold a collectible.

From 3D printing and artwork preparation to assembly, finishing, and inspection, HEXXI products are produced in small batches with a combination of digital manufacturing and hands-on work.

Here’s a look behind the scenes.

It Starts With the Design

Every HEXXI begins as a digital design.

The frame geometry, connection points, display platform, attachment locations, and other details all have to work together before anything reaches the printer.

For a HEXXI DECK, that includes the hexagonal frame and integrated display platform.

For HEXXI DECOR, the design keeps the modular hexagonal format without the platform.

The goal is not simply to create a hexagon.

The parts have to connect correctly, look clean when placed together, and work as part of the larger HEXXI system.

Then Comes the 3D Print

Once the design is ready, the HEXXI frame is produced using 3D printing.

Depending on the design, printing a HEXXI can involve different filament colors, detail lines, and other visual elements built directly into the part.

3D printing also gives us the freedom to continue developing the system without being locked into traditional mass-production tooling.

That matters because HEXXI is constantly evolving.

New colors can be tested.

New accessories can be developed.

Small design improvements can be made.

And new ideas can move from the computer to a physical prototype quickly.

Creating the Backplate Artwork

The backplate is what gives each HEXXI much of its personality.

Some designs are clean and simple.

Others are built around horror, sports, movies, holidays, landscapes, portals, clouds, or completely original artwork.

The artwork is created and prepared digitally before being printed.

From there, the image is trimmed and prepared for the finishing process.

Unlike a removable insert, the backplate becomes a permanent part of that HEXXI design.

Once the finished backplate is attached, that artwork belongs to that specific DECK or DECOR.

Finishing the Backplate

For select HEXXI designs, the artwork receives additional hands-on finishing.

The printed image is laminated and prepared before a clear epoxy finish is added.

That clear layer helps give the backplate a more finished appearance and adds depth to the artwork.

Because this process is done by hand, it is one of the stages where HEXXI moves beyond simply being a 3D-printed product.

The printed frame and finished artwork come together to create the complete display.

Bringing Everything Together

Once the frame and backplate are ready, the HEXXI can be assembled.

The finished backplate is permanently attached to the DECK or DECOR.

At this stage, alignment matters.

The artwork has to sit correctly within the hexagonal frame so the final product looks right both by itself and when connected to other HEXXI units.

For HEXXI DECKS, the platform and attachment points also need to be checked so compatible accessories can fit as intended.

Inspection Before Packaging

Before a HEXXI is packaged, it gets inspected.

We look over the print.

We check the frame.

We inspect the backplate and finish.

We make sure the overall piece is ready to become part of someone’s collection.

3D printing is an incredibly useful manufacturing process, but it is still a manufacturing process.

Small imperfections can happen.

That is why inspection is an important part of producing HEXXI in small batches.

The goal is simple:

If it has the HEXXI name on it, it should be something we are comfortable sending out.

Why Small-Batch Production Matters

HEXXI is not currently rolling off a massive factory production line.

And that gives us an advantage.

Small-batch production allows us to pay attention to the product while continuing to improve it.

We can test new ideas.

Adjust designs.

Try new themes.

Develop new attachments.

And respond to what collectors actually want to display.

That flexibility is a big part of what HEXXI is about.

The display system can grow.

And so can the products behind it.

More Than Pressing “Print”

3D printing is an important part of HEXXI, but it is only one part of the process.

There is design work.

Artwork preparation.

Printing.

Encapsulating.

Finishing.

Assembly.

Inspection.

And finally, packaging.

All of those steps come together before the finished HEXXI ever reaches the wall.

That is what makes seeing the final display so satisfying.

An idea starts on a screen.

Eventually, it becomes a physical place for someone to display something they care about.

What’s Next in the HEXXI LAB?

There is plenty more happening behind the scenes.

Future HEXXI LAB posts will take a closer look at product testing, new accessories, display ideas, prototypes, packaging development, and some of the experiments that may eventually become future HEXXI products.

Some ideas work immediately.

Others take a few tries.

That is part of building something new.

Build your display. Your way.

Get HEXXI.

Select HEXXI products are protected by U.S. Design Patent No. D1,136,687 S.