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 prowess, 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.