【3D Printing Application】Walkie-Talkie for Mines: The Full Development Process!
Maciej Burzyński, 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, specific considerations must be made for environments hundreds of meters underground. Furthermore, in the event of an accident, it must also serve as a life-saving tool to help rescue teams quickly locate survivors.
Specialized Equipment for the Mining Industry
The client, KGHM Mining Company, employs over 34,000 people worldwide and has been a major distributor of copper and silver ore for over 50 years. Key requirements included: button configuration to match past usage habits, additional protection for the "emergency button" to allow calls for help in case of an accident, and a speaker several times louder than a mobile phone due to the extremely noisy mining environment. Since mass production of the product requires injection molds costing tens of thousands of dollars, it represents a significant risk and financial gamble. Any errors during the design phase would be costly and time-consuming. In the past, without 3D printing, every stage of development, from concept to finished product, incurred enormous costs. After considering the demands for precision and strength, the designer chose to develop the product using the Sinterit Lisa SLS 3D printer.
Cost Savings in Development
In addition to printing the main body of the walkie-talkie using PA12 nylon powder, accessories such as the TPU antenna and flexible silicone buttons were also prototyped using the Sinterit Lisa 3D printer. Producing all parts with molds would have cost over forty thousand dollars. Instead of this one-time expense, the designer chose to invest in an SLS 3D printer, saving 75% of the cost and allowing for its use in subsequent projects. Previously, outsourced projects typically required several weeks and cost over eight thousand dollars. This time, the designer decided to try in-house development, which took two days and cost less than two hundred dollars. Thanks to the excellent quality of 3D printing, the design prototype could be provided to the client for testing and confirmation before proceeding with mass production molds.
Creating Added Value
Using an SLS 3D printer allows for in-house prototype testing, which streamlines working hours and reduces costs, minimizing the risk of back-and-forth errors. More importantly for the designer, it ensures absolute confidentiality for new products without needing assistance from other companies. "The 3D printer now runs smoothly; our prototypes typically take 24-28 hours to print. I just need to set up the 3D print in the morning, and by the afternoon of the next day, I can test it and secure orders," emphasizes designer Maciej. Prototype design is just part of the production process; the final product is used to ensure the safety of miners and reduce accident risks. A radio device with a 30-day continuous battery life is the most crucial product consideration in emergency response.
Rapid Return on Investment (ROI)
For businesses, the cost of the Sinterit Lisa is significantly lower than the expenses incurred from repeated mold creation and modifications. Using PA12 and Flexa Grey to produce walkie-talkie modules costs less than six hundred dollars and takes about four days. Compared to the forty thousand dollars for mold manufacturing, ROI is achieved early in the prototype development phase. Subsequent benefits, such as securing customer orders or using it for final parts, are just some of the countless values that 3D printers create for businesses. In an era where every second counts, how to reduce costs and shorten lead times through rapid prototyping is key to closing deals. (Further reading: Taiwan's Innovative Design Power Enters the European Market!)Follow our fan page to stay updated on great deals: https://www.facebook.com/3dmart.com.tw/
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