Rapid Prototyping

We use functional samples to check whether the technical design fulfills all functions using the defined materials and the intended manufacturing process. Our evaluation generally includes feasibility and—depending on the component—electrical and mechanical validation, thermal and environmental stress tests to assess product performance under extreme conditions, as well as ensuring compatibility, durability, and compliance with legal requirements.

We use visual prototypes to check manufacturability, reliability, perceived quality, appearance, and—less commonly in our case—tactile properties. The models are usually created using 3D printing and are manufactured from near-series materials for design validation testing (DVT). They give an impression of size and shape, with the focus on basic features. 3D techniques such as SLA (stereolithography) and FDM (fused deposition modeling) are cost-effective and quick manufacturing processes for producing these prototypes.

During the transition to series production, we create high-resolution, near-series prototypes with identical or very similar material properties. In product validation tests (PVT), we finally evaluate the readiness for series production, compliance with consistent quality, and subsequent processing. We conclude product development with a pilot series in which all production parameters are validated once again. To identify risks, such as dependence on a single contract manufacturer for the procurement of a specific component, we work with risk management protocols such as FMECA or FAI.

All processes are useless without the interpretation of the data. This is why we work transparently with our customers, evaluate the results together and optimize products and processes. This is also where our knowledge and experience come into play: the OKE Group is at home in many industries and knows the very different requirements for components and assemblies made of plastics and metals. We recommend changes to materials or tools, discover potential savings and weak points in manufacturing processes.

Together with our customers, we work on optimizations until everything is perfectly coordinated.