【3D Printing Application】Walkie-talkie for Mines: The Entire Development Process!
Maciej Burzyński, a product designer at Sybet, specializes in providing integrated safety equipment for the mining industry. His responsibilities include product feasibility, production and technical issues, and the success of new product launches. Unlike regular walkie-talkies, he had to consider the challenging environment hundreds of meters underground and ensure the device could help rescue teams quickly locate survivors in case of an accident.
Equipment for Mining Applications
The client, KGHM Mining Company, employs over 34,000 people worldwide and has been a major supplier of copper and silver ore for over 50 years. Key requirements included: button configurations that align with past usage habits; an "emergency button" that is extra protected to call for help even in an accident; and a speaker several times louder than a mobile phone due to the extremely noisy mining environment. Since mass production requires injection molds costing tens of thousands of dollars, it presents a significant risk and financial gamble. Any error in the design phase would be costly and time-consuming. In the past, without 3D printing, every stage of development, from initial concepts to the final product, incurred substantial costs. After considering the demands for precision and strength, the designer chose to use a Sinterit Lisa SLS 3D printer for product development.
Saving Development Costs
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. All parts, if produced through molding, would cost over forty thousand dollars. Instead of this one-time expense, the designer chose to invest in an SLS 3D printer, which not only saved 75% of the cost but could also be used for subsequent projects. Previously, outsourced projects for the company typically took several weeks and cost over eight thousand dollars. This time, the designer decided to try in-house development, and the entire process took two days and cost less than two hundred dollars. Thanks to the excellent quality of 3D printing, design prototypes could be provided to clients for testing and confirmation before mass production molds were made.
Creating Added Value
Using an SLS 3D printer for in-house prototype testing not only streamlines work time and reduces costs, minimizing the risk of errors, but more importantly for the designer—it ensures absolute confidentiality for new products without needing assistance from other companies. "Our 3D printers currently run smoothly, with our prototype designs taking an average of 24-28 hours to print. I only need to set up the 3D print in the morning, and by the afternoon of the next day, I can conduct tests and secure orders," emphasizes designer Maciej. Prototype design is merely part of the production process; the final product aims to protect miners' lives and reduce accident risks. A radio device that can operate continuously for 30 days on battery is the most critical product consideration for emergency response.
Rapid Return on Investment (ROI)
For businesses, the price of a Sinterit Lisa is significantly lower than the costs of repeated molding and modifications. Producing walkie-talkie modules using PA12 and Flexa Grey costs less than six hundred dollars and takes about four days. Compared to the forty thousand dollars for mold production, ROI is achieved early in the prototype development stage. Subsequent client orders or use for final parts are countless values that 3D printers create for businesses. In an era where every second counts, reducing costs and shortening lead times through rapid prototyping is key to securing orders. (Further reading: Taiwanese Startup Design Power, Entering the European Market!)Follow our Facebook page for great deals: https://www.facebook.com/3dmart.com.tw/
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