【3D Printing Case Study】A Complete Development Record! Mini Home Ozone Generator!
As the application of 3D printers in Taiwanese businesses continues to grow, following our last visit to "Brother Wu's Den", we were honored to be invited by a client to interview them about the development process of their new product, the "Bacteria Buster Genie"! Xetin Company, based in Taiwan, specializes in the research, development, and manufacturing of ozone generators. They currently hold multiple US invention patents. These products are used for mold removal, sterilization, and disinfection in water purification systems, restaurants, hotels, and industrial environments. Their "OxyGen Series" is exported to Europe, America, Canada, and Japan.
Challenging New Business Opportunities
Given Taiwan's hot and humid climate, in addition to large industrial products, consumers have increasingly prioritized indoor air quality in recent years. Therefore, Xetin Company began developing a personalized household ozone generator—the Bacteria Buster Genie. The early development process involved first drawing orthographic projections and then roughly cutting out the physical shape using EK board (industrial foam material) for the model. After continuous refinement and adjustments, CNC machining and mold testing were performed until the final version was ready for mass production.
However, CNC mold making is expensive, and repeated adjustments are needed to address discrepancies in material and size between the prototype and the actual product, leading to excessive mold production costs. This prompted them to start using 3D printers as a development tool, eventually choosing Ultimaker.
Prototype Elimination Round
With the Ultimaker 3D printer, experimenting with new designs became a crucial process. The "Bacteria Buster Genie" went through three design tests before becoming the final version launched on the market. The person in charge emphasized: "Originally, due to molding cost limitations, only one of the four structures could proceed to prototype testing; now, I can print all of them for actual use and then choose the best effect to offer consumers."
Unlike other products, "solid printing" was the most unique requirement in this development process. In typical 3D printed prototypes, the internal structure usually uses partial infill for shaping; however, Xetin Company, aiming for the authenticity of product material and weight, decided to directly use a 100% infill rate for testing. Since the Ultimaker significantly reduced development time and PLA filament is affordably priced, this choice was more than sufficient.
"Using the Ultimaker 3D printer allows for 100% control over the mold," said the person in charge. To meet the mini size requirements for a household ozone generator, everything from the battery casing and gasket structure to the charging dock had to be designed in-house using a 3D printer to simultaneously fulfill the internal needs of the unit.
On-Site Testing
The "Bacteria Buster Genie" household ozone generator can effectively remove mold, sterilize, and eliminate odors safely. The on-site test prototype, in addition to being entirely 3D printed, was identical to the final mass-produced "Bacteria Buster Genie" and was directly usable. Upon pressing the switch, one could even faintly sense the change in the air particles.
The Birth of the Bacteria Buster Genie XTB-360
Through continuous product prototype improvement with a 3D printer, the Bacteria Buster Genie XTB-360 was successfully launched. In addition to its compact size of 8cmx8cmx16cm, which meets various household and automotive needs, it has also passed SGS testing and certification, achieving an air sterilization rate of up to 99.9%. By saving time on mold creation and back-and-forth communication, direct communication and practical testing could be conducted within the company. The Ultimaker 2 Extended enabled more possibilities in the development process of the "Bacteria Buster Genie" and provided the best product to consumers.
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