Creating a successful design revolves around achieving the perfect equilibrium

Advanced integration in design

image of Spark employee

Michel van Schie

Throughout the design journey, one must navigate numerous compromises between conflicting design characteristics. A dynamic interplay between functionality, usability, weight, aesthetics, producibility, repairability and durability, to name a few.

Fewer parts equals more complexity

The path to an optimized product often involves integrating multiple functions into fewer parts. A strategy that not only reduces product cost but also enhances strength, reduces weight and enhances appeal. Two birds in one stone. But this comes at a price. The integrated parts will be more complex to design and will require certain production technologies. And they require the designer to oversee these opportunities and to master the growing complexity.

Taking it to the next level

Every part that can be eliminated directly impacts the cost of manufacturing, reworking, assembly and logistics. Therefore, the goal is to decrease the number of parts while fulfilling at least the same functions. Through integrating elements like mounting points and fixations, external covering and internal structural elements, optimizing topology, including use cues and reducing material usage, significant savings can be achieved and the design will rise to a next level.

Pioneering production technologies

Production technologies that employ tooling to create intricate geometric shapes in a single shot offer these opportunities. The tools required for these methods often entail significant investments But the benefits they provide often outweigh the costs, depending on volumes and margins.

If the production volumes are large enough, more integration practically always pays off

A prime illustration is the Tesla Model Y, featuring a rear underbody crafted from a single, seamlessly integrated piece. Likewise, our very own LEA care robot showcases the integration process, where a single aluminium injection-moulded part seamlessly amalgamates a sheet metal core and plastic covers.

Mastering moulding techniques

One obviously suitable production method is plastic injection moulding. Many products used on a daily basis include parts manufactured using this method, and many of the products we design at Spark also leverage its advantages. Next to this, there are numerous lesser-known alternatives for other materials, such as aluminium injection moulding, zamak moulding, lost-wax stainless steel moulding, brass forging, and EVA foam moulding, to name a few.


At Spark, we have utilized these materials and methods, constantly making trade-offs among them for hundreds of products throughout our existence. We specialize in determining the optimal investment versus cost strategy for our clients' products, often resulting in highly integrated products that provide increased value while saving costs and generating long-lasting revenue.

Conducting a designer's symphony

In the symphony of design, where integration conducts a harmonious melody, we continue our pursuit at Spark. With each project, we navigate the intricate notes, blending innovation and expertise to compose masterful designs. As our journey unfolds, we remain dedicated to achieving the perfect equilibrium, orchestrating every element to create products that transcend expectations and stand as a testament to the artistry and precision that defines us.


Join us as we explore new crescendos and craft timeless compositions, pushing the boundaries of integration and design. For in the realm of innovation, the symphony never truly ends—it simply evolves, resonating with the ever-changing needs and aspirations of a world seeking seamless, elegant solutions. Together, we compose the future.

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