Maciej Burzyński, a product designer at Sybet, specializes in providing integrated safety equipment for the mining industry. His responsibilities encompass product feasibility, production, technical issues, and the effectiveness of new product launches. Unlike ordinary walkie-talkies, these devices must be designed for use hundreds of meters underground, and in the event of an accident, they must also serve as a life-saving tool to help rescue teams quickly locate survivors.
The client, KGHM Mining Company, has over 34,000 employees worldwide and has been a major supplier of copper and silver mines for over 50 years. Key requirements included: button configuration must conform to past usage habits; the "emergency button" needed extra protection to call for rescue in case of an accident; the mining environment is extremely noisy, and the speaker of the radio would be several times louder than a mobile phone, etc.
Mass production of goods requires injection molds costing tens of thousands of dollars, which is a huge gamble both in terms of risk and finance; any mistakes in the design phase will come at a costly and time-consuming price. In the past, before 3D printing , every stage of development, from the initial stage to the finished product, required a huge amount of money. However, after considering the requirements for precision and strength, the designers chose to use the Sinterit Lisa SLS 3D printer to develop their products.
Besides using PA12 nylon powder for printing the main body of the walkie-talkie, accessories such as the TPU antenna and flexible silicone buttons were also prototyped using the Sinterit Lisa 3D printer . Manufacturing all parts by mold would have cost over $40,000. Rather than a one-time expense, the designers chose to invest in the SLS 3D printer equipment; this not only saved 75% of the cost but also allowed for future projects. Previously, outsourced projects at this company averaged several weeks and cost over $8,000. This time, the designers decided to try in-house development, which took two days and cost less than $200. Because of the superior quality of 3D printing , the design prototypes could be tested and confirmed by the client before mass production molds were made.
Using SLS 3D printers allows for in-house prototyping, streamlining work time and costs, reducing the risk of errors, and, most importantly for designers, ensuring absolute confidentiality of new products without the need for external assistance. "Our current 3D printers operate smoothly; our prototype designs typically require 24-28 hours of printing. I only need to set up the 3D print in the morning, and I can test and secure orders the following afternoon," designer Massey emphasized. Prototyping is just one part of the production process; the final product is used to ensure miners' safety and reduce accident risks. Wireless equipment capable of 30 days of continuous battery use is a crucial product consideration in emergency response.
For businesses, the price of the Sinterit Lisa is far lower than the cost of back-and-forth mold making, modification, and remanufacturing. The cost of producing walkie-talkie modules using the PA12 and Flexa Grey models is less than $600 and takes approximately four days. Compared to the $40,000 cost of mold making, a return on investment (ROI) is achieved early in the prototype development phase. Subsequent customer orders or use in final parts demonstrate the immense value that 3D printers create for businesses. In this fast-paced era, the ability to reduce costs and shorten delivery times through rapid prototyping is crucial for securing orders. (Further reading: Taiwanese startups' design capabilities advance into the European market! )
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