High‑Volume Prototype Protection for Low‑Voltage Connectors
Rapid Prototyping
Volume Readiness
Serial Readiness
Accelerated Prototyping for Electrified Driveline Applications
A rapid, cost‑balanced prototype solution enabling early functional validation and supporting critical timelines for an electrified driveline program.
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About Our Partner
A global supplier to the automotive industry, operating in complex manufacturing environments where product quality, protection, and traceability are critical.
Challenges
Strict Timing Requirements
The project was driven by tight downstream milestones, creating urgency and pressure on prototype availability.
Unusually High Prototype Volumes
Required volumes significantly exceeded standard low‑shot samples while still needing production‑like material behaviour.
Risk of Early Development Commitment
Traditional prototyping approaches introduced risks in lead time, cost and flexibility when design revisions were required.
Our Solutions
Additive‑Manufactured 3D Molds
Proposed a non-traditional prototyping process enabling fast lead times, controlled molding conditions and production-intent parts made from final materials.
Phased Delivery Structure
To support validation and risk mitigation:
First shipment - within 2 weeks
Second shipment - per request 3 weeks later.
All production controlled internally for speed and quality.
Transparent Technical Communication
Clear guidance on technical limits.
Reprinting required if design changes occur
This transparency strengthened trust and credibility.
Custom Engineering Support
Four of the five protective solutions were fully designed and validated internally, including rapid mold production (~3 days) and first batch molding within 72 hours.
Value-Added Services
Beyond part design and manufacturing, DBI provided:
Tailored designs ensuring secure fixation, optimal coverage, and repeatable installation.
Fast‑Track Tooling & Molding
A fast-track development approach supported by early-stage additive manufacturing for sample validation, enabling rapid lead times and production-representative molded parts.
Flexible Supply & Delivery
Structured, phased shipments aligned with validation milestones, supporting program speed while reducing risk.
Collaborative Engineering Support
Close cooperation between engineering and technology teams, enabling quick adjustments, transparent communication and full in‑house process control.
Results & Impact
Program Acceleration & Prototype Validation
The approved prototype strategy enabled accelerated validation and early functional testing. Timely delivery of prototype batches ensured program confidence and supported the achievement of critical development milestones.
Foundation for Serial Production
The successful prototype execution secured the award of the shipping cap program. A portion of the serial tooling investment was absorbed to ensure design ownership and long‑term product positioning — strengthening the strategic value of the collaboration.
Strategic Business Impact
This outcome represented far more than a prototype achievement. It became a gateway into long‑term program involvement by:
Turning prototype success into a serial production award
Expanding the portfolio of low‑voltage protective solutions
Demonstrating capability as a problem‑solving development partner, not only a manufacturer
Establishing a repeatable, fast‑execution prototype model applicable to future customer programs
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