For Ford Waasland Automotive, Brocken Dynamics produced an initial series of custom-made phone holders for use within Bpost's logistics activities. The holders were developed for daily professional use and had to meet high demands in terms of sturdiness, temperature resistance, durability, and ease of use.
From design to production
After the design was approved, production started using industrial 3D printing technology. This production method made it possible to produce the parts quickly and cost-effectively, without the need for expensive molds, while ensuring consistent quality throughout the entire production series.
As a personalized detail, the bpost logo was subtly integrated into the phone holder's design. This gave the final product a professional appearance that perfectly matched the end-user's corporate identity.
Material selection
For this project, PA612-CF15 was chosen, a polyamide (Nylon) reinforced with 15% carbon fiber. This material combines high stiffness, excellent wear resistance, and low weight, making it particularly suitable for functional parts that are subject to intensive daily use.
An important reason for this material choice was also the high-temperature resistance of PA612-CF15. Because the phone holders are permanently used in vehicles, they must be able to withstand the sharply rising temperatures that can occur in a car during hot summer days. Thanks to the thermal stability of this material, the shape and mechanical strength of the part are maintained, even with prolonged exposure to higher temperatures.
Assembly and finishing
After 3D printing, each phone holder was carefully finished and fully assembled. The following components were added, among others:
- Brass screw inserts for durable and reliable fastening.
- Protective PU foam pads to securely hold smartphones and prevent damage.
- Rubber O-rings at the bottom to hold the charging cable.
- A rotary knob, also printed in PA612-CF15, which is bonded with thread.
After assembly, the phone holders were packaged and delivered as a first production series.
The result
This project demonstrates that 3D printing technology is not only suitable for prototypes but also for the efficient production of high-quality finished parts in small and medium-sized series. By combining engineering, high-quality materials, and a precise production and assembly process, Brocken Dynamics was able to deliver a durable solution that fully meets the requirements of a professional work environment.
Does your company need a technical part, a functional prototype, or a small to medium-sized production series? Brocken Dynamics guides the entire process, from design and material selection to production, assembly, and delivery.
