72-hour prototype iteration loop for a centre console

The problem

A studio needed to validate the feel and fit of a new centre console while the design was still being finalised, but their internal prototyping queue was two weeks deep.

What we did

• Built the parametric CAD from the studio's surface data, keeping the model live so changes could be pushed through quickly.
• Ran three rounds of SLA and SLS prototypes in under two weeks, covering the console body, the lid hinge and the cup holder inserts.
• Fed the fit findings directly back into the model between rounds instead of collecting them into one late report.
• Issued a DFM feasibility note covering the eventual injection tooling.

Result

The design was frozen two weeks earlier than the original plan, and the injection tool was cut against a model that had already been validated in the hand.