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Kevin Forde
Design Engineer,
Cork Design Center
Logitech Ireland Services
Logitech Services save design costs and improve confidentiality thanks to Objet’s Eden™ 3-D printing system
The Design Center at Logitech Ireland Servises is a development
hothouse for Logitech’s popular high-end retail computer mice, digital
pens, digital presenters, remote controls and other pointing devices.
In seeking to improve their design process, the design team
researched its 3-D printing options in depth. Early on, they discovered
that the technology and solutions available at the time (in 2002 and
2003) did not meet their stringent requirements. They found the
complexity and lack of accuracy of most systems, along with their high
demands on operator time and skills, disappointing, and so decided to
wait for a more complete solution.
“It was clear to us that fit, form & function tests were essential to our
design process and so we absolutely had to have a system that could
produce highly accurate, high-resolution parts,” said Dennis O’Keeffe
Director Cork Design Center, Logitech Ireland Services.
Eden330 chosen for its accuracy and materials
After
two years of research, Logitech selected Objet’s Eden330™ 3-D printing
system, choosing the Objet system for its high quality models and
because of the variety of materials it supports. In particular Objet’s
FullCure® Tango line of flexible, rubber-like materials captured the
design team’s interest as it would enable them to model the “feel” as
well as function of the grip elements of Logitech’s electronic pointing
devices.
The Eden330 was installed in August 2004. For the past few
years, it has enabled the Logitech design team to cost effectively and
efficiently explore creative ideas, precisely test fit, form and
function, reduce the cost of design errors, and preserve the
confidentiality of its products in development.
“Having Objet
internally is a big bonus,” said Kevin Forde, Design Engineer at
Logitech. “External prototyping of parts takes three days, but now I
have my solution within one day. The ability to do ‘unofficial prints’
– when we spontaneously send a print for design – has changed the
entire process flow of our product design.”
Putting 3-D models to work at every stage
Logitech uses the Eden330 throughout the design process.
Concept
modeling – First, the concept model is printed, enabling close
collaboration with the marketing department. Often, the team prints
multiple variations of the same model, enabling all stakeholders to
evaluate the various aspects of the product, such as thumb and grip
positioning and button locations.
High-level design review – Objet
models are used to perform rough fit and form testing of the different
components. Lower-lever design review – More in-depth fit and function
tests are performed. All elements, such as shell, buttons and rollers,
are produced on the Eden330 and fitted; the buttons and optical laser
beam are also tested for function. The PCB is then fitted into the
model, along with all components.
Production initiation – The 3-D files are sent for manufacture in logitech’s
manufacturing
plant. The products are manufactured and assembled and then units are
sent back to the Cork Design Lab for testing. The Objet prints are used
here to build fixtures to help in the debug process, saving cost on
expensive machined fixtures.
Kevin Force noted: “Our products are
getting more and more complex, requiring more accurate fit testing.
Being able to print fixturings, which typically need to be altered two
or three times, has saved vital time and costs. Whereas fixturings were
commonly made of metal and outsourced at a high cost, we can now do
this in-house.”
Using 3-D modeling to support the creative process and ensure confidentiality
Logitech
constantly strives to introduce real innovations to the market. Using
the Eden330, designers are able to try out their ideas free from the
cost and time constraints imposed by traditional outsourced prototyping.
“We
don’t need to think of the hassles that come with the standard
prototyping and outsourcing of parts,” said Kevin Forde. “Using the
Eden330, we can print any part deemed necessary. That fundamentally
encourages people to try different design solutions.” Keeping creative
ideas confidential until a product is launched is critical in
Logitech’s highly competitive market. Commented Kevin Forde: “We live
in a very aggressive
market environment, with a lot of competition,
so reducing the number of contacts with the outside world is
indispensable for our product’s success. Having Objet inhouse helps us
reduce exposure.”
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