Virtual relationship delivers the goods

Called FROG, the new device generates alarms in the event of heavy rainfall, river or urban flooding or water distribution bursts. It is made by Isodaq Technology, a division of Herefordshire-based Hydro-Logic Ltd. Isodaq designed two end-caps to seal the extruded body. Creating these polycarbonate caps to match the unusually shaped extrusion was a challenge. With annual production volumes expected to run to hundreds (or possibly low thousands), the 30-employee privately owned company needed to source a cost-effective manufacturing solution. The company initially looked at commonly available forms of rapid prototyping such as FDM and SLA but decided that there would be no substitute for testing with real injection moulded parts. However, the anticipated volumes for FROG could not justify the cost of expensive steel production tooling demanded by conventional injection moulding techniques. "We searched online and considered many different options before we came across details of Protomold's rapid plastic injection moulding process," says the company's products director for the Isodaq range, Tim Campbell. "The website says from 3D CAD to real plastic parts in production intent material as fast as the next day, which caught our attention." Another advantage which impressed Hydro-Logic was that Protomold uses advanced aluminium alloys to produce multi-cavity moulds that can be guaranteed for the life of the project if required, thus supporting ongoing production as well as prototyping. Hydro-Logic used ProtoQuote, Protomold's online service that allows potential customers to submit 3D CAD models and receive an automated quotation. Users get pricing, options, and, if appropriate, suggested changes for improved mouldability. ProtoQuote accepts uploads in IGES, STEP, SolidWorks, ProE, Parasolid and ACIS formats. "We were all very impressed with ProtoQuote," says Mr Campbell. "Within a few hours we had a comprehensive, interactive online quotation coupled with feedback on design and mouldability. While viewing the quote, it was possible to adjust parameters such as resin, finish and part quantity through the ProtoQuote 3D viewer, and the price adapted in real time to reflect the new input. Ultimately, the prices we received for both the tooling and the parts were much less than we expected." The project was given the 'green light' and Protomold produced the rapid injection mould tooling and 400 end caps, ready to be fitted to the first 200 Isodaq FROG units. "To be honest, Protomold has been so efficient that the end caps are actually the first completed parts we have received for FROG," says Mr Campbell. "We are all impressed with the end result – even the colour. Some people were sceptical that Protomold could match the green RAL colour that we specified, but they were wrong! The match is perfect. It's now down to our extrusion supplier to do an equally good job." The entire end cap project has been completed online via Protomold's ProtoQuote process. "Although we've never met face-to-face, the process could not have been any simpler," says Mr Campbell. "The fact that Protomold has delivered these parts quickly and at an affordable price ensures we keep our costs as low as possible, which is one of our top priorities for FROG."