From 6 weeks to 2 days

The challenge

Traditional prototyping requires a steel tool before the first functional prototype can even be moulded. That means weeks of waiting and a high cost per iteration — a real barrier to trying out several design variants before a product is released for production.

The solution: Carmo Print Moulding

Drawing on more than 70 years of injection-moulding expertise, Carmo has built a modern hybrid production model by introducing additive manufacturing (AM) alongside its traditional production. Instead of waiting for a steel tool, we 3D-print the mould and injection-mould the prototypes — so we can deliver functional prototypes in materials that match the final product in just 1–2 days, instead of up to six weeks. Read more about Carmo Print Moulding and rapid prototyping.

The method is a gamechanger. It makes it possible to produce prototypes much faster and at the same time makes it easier to adjust the design along the way, as it is possible to create multiple iterations. This shortens the overall manufacturing process and reduces costs.

Anders Johnsen, VP R&D and Technology, Carmo A/S

The result

Prototype lead time has gone from up to six weeks to 1–2 days. This makes it possible to run more design iterations at a fraction of the cost, make decisions faster, and significantly reduce risk by testing new products before investing in production tooling — while opening up new market opportunities.

Independent validation

The project was carried out together with Dansk AM Hub — the industry’s independent innovation partner, which is initiated, developed and supported by the Danish Industry Foundation (Industriens Fond) and operates independently and impartially, without selling machines or technology. Read the independent case at Dansk AM Hub →

Results

• Prototype lead time: from up to 6 weeks to 1–2 days
• Functional prototypes in materials that match the final product
• More design iterations at lower cost
• Reduced risk when testing new products
• Faster time to market