Case study · Prodigy
From concept to production
Prodigy had a product to launch and a sketch. We did the design, the prototypes, then the production of the tube structure.
- 1
- sketch to start
- 2
- prototypes before the run
- 3
- operations under one roof
The client’s problem
The product existed as a sketch and a hand-made prototype. It needed a manufacturable 3D model, a unit price and a supplier able to keep up with the launch.
Having a drafting office design it, a shop cut it and another weld it would have multiplied the back-and-forth before the first sellable unit.
What he sent us
- A hand-dimensioned sketch and photos of the hand-made prototype.
- The usage constraints: load, maximum dimensions, desired finish.
- A launch quantity and a twelve-month target quantity.
What we changed in the design (DFM)
- Full 3D modelling by our draftspeople, from the sketch.
- Structure redesigned in square tube with laser-coped joints, instead of bent parts welded end to end.
- Fewer welds, with joints moved away from visible surfaces.
- Powder-coat finish planned from the design stage, with built-in hanging points.
How we produced it
- 01
First prototype
Structure cut and welded, tested by the client in real use.
- 02
Second prototype
Two dimensions adjusted and a brace added from the tests. Approved in writing.
- 03
Launch run
Laser cutting, MIG and TIG welding, coordinated powder coating. First run delivered, then lots following sales.
The result
A product taken from sketch to series with one point of contact. The 3D model, drawings and cutting program belong to the client and serve every lot.
The client has a product and a plant. He did not have to become a subcontractor manager.