LKprototype offers free prototype design review to global clients. Its experienced staff reviews over 4,500 design projects annually in 12 sectors like consumer electronics, medical devices, and automotive parts. With the AI-driven design analysis system (error rate ≤0.8%), engineers are able to simulate structural strength (load range 0-5,000N) in 24 hours, carry out tolerance superposition analysis (accuracy ±0.05mm) in 24 hours, and obtain material cost optimization suggestions (average cost savings 15%) in 24 hours. For instance, the housing design of the insulin pump tested in a specific American medical device corporation in 2023, through adjusting the thickness of the wall (from 2.2mm to 1.8mm) and optimizing the reinforcing ribs’ density distribution (from 6 strands /cm² to 9 strands /cm²), with the impact strength ≥80J/m, reduced the injection molding cycle by 18% and the material cost by 37%. Save customers $8,200 in the first round of proofing.
The complimentary design review feature integrates the DFM (Design for Manufacturability) and DFA (Design for Assembly) methodologies and can identify over 90% of the possible process risks. According to the Q1 2024 data statistics, its review suggestions reduced customer prototype changes by 63%, and reduced the average project delivery time to 55% of industry average (from 14 days to 7.7 days). Taking a certain German industrial sensor company as an example, LKprototype found the heat dissipation design flaw of the PCB board by thermodynamic simulation (temperature range -40℃ to 120℃), and re-designed the copper foil thickness (from 35μm to 70μm) and the vias distribution (from 120 /cm² to 180 /cm²). The maximum operating temperature was reduced from 98℃ to 72℃, product life was extended to 50,000 hours (the MTBF was raised by 40%), and the unit cost was reduced by 22% via supply chain integration.
In compliance review, the professional team of LKprototype has 28 international certification qualifications such as ISO 13485 and IATF 16949 that can assist in ensuring that the design complies with the regulatory requirements of the target market. For instance, a specific Chinese drone manufacturer failed multiple tests due to EMC (Electromagnetic Compatibility) issues in the EU CE certification. LKprototype enhanced the motor shielding cover’s coating thickness (from 3μm to 8μm) and grounding path impedance (from 0.15Ω to 0.06Ω) through free review. Pass the EN 55032 Class B standard once, save money on repeated tests by $15,000, and advance the time to market of the product by 6 weeks. During the process, the group used the signal integrity analysis tool (bandwidth of 1GHz) to determine the interference source. The rectification plan reduced the strength of electromagnetic radiation to a high of 42dBμV/m (below the 50dBμV/m threshold).
From the aspect of cost, free design review services significantly improve the return on investment (ROI) for clients. Statistics for 2023 show that the success rate of mass production in reviewed projects is up to 92%, which is 58% compared to that of non-reviewed projects. A Japanese robot joint manufacturer, through LKprototype’s topology optimization suggestions, trimmed the weight of aluminum alloy components from 850g to 620g (27% less), lowered the drive motor power demand from 120W to 85W, and reduced overall energy consumption by 29%. Electricity costs are projected to be saved by $12,000 over the life cycle. During the review, the team utilized stress cloud map analysis (with grid accuracy of 0.2mm) to redistribute the load path, increasing the safety factor of the critical elements from 1.8 to 2.5 and the fatigue life to over 10^7 cycles.
For further information regarding LKprototype’s single-stop manufacturing processes such as rapid prototyping, CNC machining, vacuum casting, and 3D printing, as well as the core advantages of its own factory in quality control, quick shipping (completed within 3 days), and no order quantity, please visit the official website for further exploration: https://lkprototype.com/