From Prototype to Production: A Case Study on Seamless Manufacturing with DTG

The theoretical benefits of plastic prototype manufacturing are clear: validate designs, reduce risk, and save costs. But how do these principles translate into a real-world success story? This case study details our collaboration with “MediTech Innovations” (a fictional name for a real client) to illustrate how a strategic partnership in prototyping paves the way for a flawless transition to mass production.

The Client Challenge: A Critical Medical Device Housing
MediTech approached DTG with a sophisticated design for a portable diagnostic device housing. Their project had non-negotiable requirements:

1. High Volume: They needed an initial batch of 200 housings for extensive clinical trials and beta testing, with a clear path to mass production of 50,000+ units annually.
2. Material Integrity: The parts had to be made from a medical-grade, sterilizable ABS/PC blend to ensure durability and chemical resistance.
3. Aesthetic & Functional Quality: The housing required a textured, medical-grade finish and had to snap-fit perfectly with internal components without any flash or defects.
4. Timeline: The project was on a critical path, and delays in part delivery would have set back their entire clinical schedule.

The DTG Solution: A Strategic, Two-Phase Approach
We recommended a two-phase strategy that aligned perfectly with their needs and de-risked their entire production plan.

Phase 1: Low-Volume Injection Molding for Validation
Instead of costly and less representative CNC-machined housings, we proposed low-volume injection molding.

• Rapid Aluminum Mold Manufacturing: Our mold-making team immediately began fabricating a single-cavity aluminum mold designed for their projected volume of 500 parts.
• Integrated DFM (Design for Manufacturability): Before cutting metal, our engineering team performed a thorough DFM analysis. We provided a detailed report highlighting potential issues, such as optimizing wall thickness for even filling and adjusting gate locations to minimize visible vestiges. This collaborative step ensured the design was perfected for the molding process.
• Production-Identical Parts: Within 3 weeks of project initiation, we delivered the first 200 housings. The parts were flawless—they had the exact material properties, strength, and medical-grade texture required. They assembled perfectly and performed without issue in the clinical trials.

Phase 2: Seamless Ramp-Up to Mass Production
The success of Phase 1 made Phase 2 remarkably straightforward.

• Validated Design Data: The low-volume production run served as the ultimate design validation. We had already proven the part was manufacturable and that the final design was optimal. There were no surprises.
• High-Volume Steel Mold Fabrication: While the clinical trials were underway, we began manufacturing the high-volume, multi-cavity production mold from P20 steel. The design data from the successful aluminum mold accelerated this process.
• Mass Production Injection Molding: The transition to mass production was seamless. Because the part design and manufacturing process were fully validated, we were able to immediately begin producing high-quality parts at a scale and cost that met MediTech’s ambitious targets.

The Result: Trust Built Through Partnership
MediTech successfully navigated their clinical trials and launched their product to market without any manufacturing-related delays or costly design revisions. By choosing DTG as an end-to-end partner, they avoided the common pitfalls of switching manufacturers between prototype and production.

This case study underscores a core principle: plastic prototype manufacturing is not an isolated service but the first step in a manufacturing partnership. When your prototype provider is also your mass production expert, you eliminate friction, ensure consistency, and protect your investment every step of the way.

Your Product Deserves the DTG Advantage
Are you ready to de-risk your product development and ensure a smooth journey from concept to customer? Partner with DTG, where prototype development, mold manufacturing, and mass production injection molding coexist under one roof.

Contact us today to discuss your project. Submit your CAD files for a free, no-obligation DFM analysis and quote, and let’s build your success story together.

FAQ:

• Q: How does prototyping with DTG differ from using a dedicated prototype shop?
  A: The key difference is seamless scalability. A prototype shop can make your parts, but DTG ensures those parts are perfectly optimized for a smooth and efficient transition to the high-volume production that we also provide. We build your future production success into the prototype phase.
• Q: Do you provide DFM analysis for all prototype projects?
  A: Yes, we integrate a comprehensive DFM analysis into our quoting process for all projects, especially those involving CNC machining and injection molding. It’s a core part of our value proposition, ensuring you receive a part that is not only high-quality but also designed for manufacturability.