【3D Printing Case Study】A Complete Record of the Development Process! 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, from Taiwan, specializes in the research and manufacture of ozone generators and currently holds multiple US invention patents. These products are used in water purification systems, restaurants, hotels, and industrial environments for mold removal, sterilization, and disinfection. 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 become increasingly concerned about the quality of their home environments 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 roughly cutting the physical shape using EK board (industrial foam material) for the model. After continuous revisions and adjustments, CNC machining and mold testing were conducted, and only after the final version was approved did it enter mass production.
However, the cost of CNC molding is expensive, and there are repeated adjustments needed for material and size discrepancies between the prototype and the actual product, leading to excessive costs from repeated mold production. This led them to start experimenting with 3D printers as a development tool, ultimately choosing Ultimaker.
Prototype Elimination Race
With the Ultimaker 3D printer, trying new designs became a very important process. The "Bacteria Buster Genie" went through three different shape tests before becoming the final version launched. The person in charge emphasized: "Originally, limited by the cost of mold making, only one of four structures could enter prototype testing; now, I can print each one out for actual use and then choose the best effect to offer consumers."
Unlike other products, "solid printing" was the most special requirement in this development process. In general 3D printed prototypes, internal structures mostly use partial infill for shaping; however, Xetin Company, in pursuit of the authenticity of product material and weight, decided to directly use a 100% infill rate for testing. Since Ultimaker greatly reduced development time and PLA filament is affordable, this choice was still more than sufficient.
"Using an Ultimaker 3D printer allows for 100% control over the mold," said the person in charge. To meet the mini size requirements of a household ozone generator, everything from the battery casing and gasket structure to the charging base had to be designed internally using a 3D printer to simultaneously meet the internal needs of the device.
Actual Testing in Action
The household ozone generator "Bacteria Buster Genie" can effectively remove mold, sterilize, and eliminate odors safely. The test prototype at the site, apart from being entirely 3D printed, was identical to the final mass-produced "Bacteria Buster Genie" and was a directly usable product. After pressing the switch, one could even faintly sense the change in air particles.
The Birth of Bacteria Buster Genie XTB-360
Through continuous product prototype improvement with 3D printers, 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%. Saving time on mold making and back-and-forth communication, direct internal communication and actual testing were 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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