Cases

Jeroen op ten Berg . GBO DESIGN - ENGINEERING

GBO and development associates:

GBO DESIGN - ENGINEERING is founded in 1990 by Jacques Gramser, Erwin Boes and Jeroen op ten Berg.
The team has now increased to 16 "creative designers and engineers". We develop both professional and consumer products for different markets in Helmond, the Netherlands (20 minutes away from the Belgian border). The product development process can be guided from concept development, engineering, rapid prototyping up to support of 0-series. A good collaboration with development associates is essential for a fast and high-quality product development. Materialise is an outstanding example of this.
GBO has several well-known customers including Volvo Styling Europe, Ahrend, Matsushita (National/Panasonic), Henkel, Pelikan etc. In the last few years we have built up a considerable clientele in Belgium. GBO often gives presentations in educational institutes and organisations.
This year, for the third time, GBO will have a stand on the "Plastics for the Industry" fair in Kortrijk, Belgium (27 - 29th April 2004) where Materialise will also be present. "An enormous success", according to the GBO management, "because we can do good business here in an informal atmosphere". This show is always a very successful event to maintain relations with existing customers and present ourselves to potential customers. Some references in the Belgian market are a.o. Samsonite, DMS, Plastiflex, Niko, Penne, Vandemoortele, Loomans, Meyvaert, Recticel and Boucherie. In the short term we are planning to open a GBO branch in Belgium in order to liase more closely and efficiently with our clients and suppliers.

Design and rapid prototyping:

During the design process, rapid prototyping is a regularly used tool. We notice that our customers are requiring more and more to have a clear image of the size and style of their new product. It has proven to be very beneficial in testing a brand new concept.
GBO develops the first concepts by means of the software Rhino. The new cycle lock collection of AXA (photo 1) is a clear example of this. In an early stage the customer wants to inform a certain department - for instance the marketing team - in detail about the new product. With the help of STL-files from Rhino we can have 3D stereolithography models made by Materialise in 3 days.
As the result is crucial, it is of major importance that we inform the customer regularly about the status of the design process. After all, all living hinges, wall thicknesses, and the like are not yet known. Nevertheless, it is possible to see and touch the volume. It is not uncommon that the product is perceived in a totally different way than when it is presented on a screen or piece of paper.

Photo 1. AXA cycle lock collection

Engineering and rapid prototyping:

In the engineering phase GBO works with Unigraphics. Mainly due to the optimisation of the scale graduations, the specification of constructions, the computing of fixings are part of this engineering phase.
We have developed a videophone for Ex'ovision, the "Eye Catcher" (photo 2), which makes it possible to communicate with eye contact. The functional display is reflected in a mirror that lets passing the light and behind which a camera is placed. A totally new product designed for an existing market. This customer asked us to build a couple of models during the engineering phase to be able to judge the functionality and to present the concept to possible buyers. More than 10 scale components have been constructed in plastic. All these 3D parts were produced by Materialise originating from an STL-file.
Following the success of the prototypes a further 30 prototypes were requested that had to be similar to the eventual production series as they wanted to present the new product to the public. Within 6 weeks all PUR models were made by means of silicone moulds (Vacuum casting). As soon as the parts were delivered we began the final assembly (photo 3).

Photo 2. Ex'ovision design                                                               Photo 3. Ex'ovision assembly

Different models were presented at international trade shows in the Netherlands and far beyond, so the product could be evaluated on its functionality. The LED lighting is visible through the transparent cast housings. The progressive design of the keyboard is finished in anthracite tints.

This phase was extremely important for this kind of project. We prepared a plan to ensure all of the details were available. We had contact on a regular basis to discuss the specifications and qualities that the products had to meet.

At GBO we have our own tool shop, so if there are any last minute adjustments to be made, we have the facilities available for example sandblasting or coating. Together with our development partners we look into the right division of tasks and in particular into the qualities of which the parts need to be delivered.

We predict growing possibilities for having prototypes built at an even earlier stage of development. An other significant development is the collaboration with manufacturers in the Far East. Rapid prototyping can serve as a valuable means of communication here. Also for machine manufacturers we notice more and more possibilities to set in rapid prototyping for the composition of the first machines. The amount of integrated metal parts that are afterwards made in plastic is rising. It is of crucial importance that it is tested in an early stage of the process.

GBO Design-Engineering and Materialise:

Why does GBO DESIGN - ENGINEERING choose Materialise? Firstly because Materialise is capable of building large SLA parts, something exceptional in Europe. The second reason why we find Materialise an extremely suitable partner is their large series/volume capacity, the short lead times and the quality check. In addition to all of this, the Materialise team gives expert advise about the specific techniques and materials that should be used for your project - something which is done on their own initiative. The whole communication process goes very smoothly because Materialise can handle the STL-files that are made in Rhino.