Best practice: Successful technology consulting for a start-up From prototype to innovative camping toilet
© TRELINOThe challenge: An innovative start-up approached IKV to realise the transition from the production of hollow body prototypes using rotational moulding to series production using injection moulding. The aim was to develop a lightweight, robust and user-friendly camping toilet. The changeover posed considerable technical challenges, including the reworking of the components to suit the material and production process as well as the design of a suitable injection mould. A particular challenge was to reconcile the individual design requirements of the start-up with the technical requirements of the injection moulding process.
Material selection
The choice of material played a central role, as the end product had to meet various specific requirements:
- Mechanical: High load-bearing capacity and stability to make the product both durable and strong.
- Chemical: Resistance to cleaning agents and environmental influences such as UV radiation or moisture.
- Electrical: Integrated functions such as sensors or controls for certain comfort features had to be supported by suitable materials.
IKV carried out detailed research:
- Evaluation of relevant specialist literature and material databases to identify possible candidates.
- Targeted inquiries to material manufacturers to obtain specific information on availability, costs and processing properties.
The result was a structured overview of potential materials, including important characteristic values such as tensile strength, chemical resistance and dimensional stability. A list of suitable commercial products was also provided, which served as a basis for further decisions.
Bauteiloptimierung und rheologische Auslegung
The original prototypes from rotational molding had to be adapted to the requirements of injection molding in terms of both function and production technology. This included
- Design variants: IKV developed several design drafts that took into account both the mechanical requirements and the aesthetics.
- Simulations: Detailed injection molding simulations were carried out for each variant in order to:
- wall thicknesses without jeopardizing stability.
- ribs for additional stability at critical points.
- Optimally define the injection point to ensure uniform mold filling and minimal material inclusions.
- shrinkage and warpage to ensure dimensional accuracy and functionality.
The result of this process was two optimized geometries that met both the functional requirements of the camping toilet and the technical process conditions of injection moulding.
Thermische Auslegung und Werkzeugkonstruktion
The development of a suitable injection mold was an essential step in enabling the transfer to series production. IKV took a systematic approach to this:
- Thermal simulations: Analysis of mould cooling to ensure uniform temperature distribution and optimize cycle times.
- Positioning of ejectors: Detailed planning to enable easy demolding of finished components without damage.
- Ease of assembly: The moulds were designed to be easy to maintain and flexibly adaptable.
After completing the simulations and design work, IKV presented two tool concepts as detailed CAD models. These concepts were coordinated with the start-up and adapted to the requirements of the selected toolmaker.
Einholen und Bewerten von Angeboten
Based on the specifications drawn up, IKV prepared a detailed tender for toolmaking. Several toolmakers were contacted in order to obtain offers that took into account both the technical requirements and economic aspects. IKV comprehensively evaluated the bids received, in particular with regard to
- Manufacturing feasibility
- Cost structures and price-performance ratio
- Delivery times and services of the providers
After an in-depth consultation, the start-up decided on a suitable toolmaker. IKV supported the order, carried out technical coordination and ensured that the molds met the specifications exactly.
Dr.-Ing. Christoph Zimmermann
Head of department Injection Moulding and Additive Manufacturing
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