Crown Product Line: Complex Surface Design Engineered for Injection Molding

Crown Product Line: 3D Printed Prototypes for Pre-Tooling Validation

Our client came to CADLETE Designs with a complex product line featuring highly detailed geometry and significant surface detail. The goal was to turn this intricate concept into a practical product that could be manufactured.

We developed the complete product design through more than 20 design revisions, refining geometry, surface details, proportions and structure, and engineered the products to be compatible with injection molding.

With designs this detailed, screens only tell part of the story. We produced functional 3D printed prototypes so the client could physically see, handle and review every product before moving toward tooling. This step makes it far easier to spot issues with proportion, detail and fit while changes are still quick and inexpensive.

For the soft rubber cover, which had complex undercuts and needed a production-like finish that 3D printing could not achieve, we produced a small batch of functional prototypes through vacuum casting in a silicone-like rubber material. Backed by physical validation, the project is now moving toward manufacturing, with an injection molding DFM review underway.