Materials choices for mass manufacturing preparedness
Addressing a key challenge of those placing a physical product on the market, the Hub’s resident product development specialist, Andrew Jack of Hub Member Hone.pd, delivered a deep dive into material selection and its impact on the way from proof-of-concept to manufacturing.
Andrew offered a glimpse behind the scenes of product development, highlighting different materials and technologies, and their characteristics - how they behave, where they excel and what to avoid when progressing a product from proof-of-concept all the way to a product that will be mass-manufactured. He covered a broad spectrum: from ferrous and non-ferrous alloys to composite materials, and the particular advantages of 3D printing – especially when creating a part for the first time and exploring its future form and function. We also touched on high-tech 3D printing such as foams with varying densities and discussed perspectives contributed by participants from medtech and architectural design.
The session felt like a complete and enjoyable course in materials science and manufacturing technology. We came away with an understanding when CNC or EDM machining is appropriate, how laser cutting compares to plasma cutting, and importantly - how cost and strategic considerations factor into these choices: How many cycles can a mould withstand? At what production volume does the cost for a mould break even?
Andrew conveyed an understanding of the challenges at hand. A powerful message was the importance of selecting technologies and materials that genuinely fit the customer’s needs. Using the example of a purpose-built laboratory product, Andrew showed how a material can be fundamentally unsuitable if it interferes with the user’s research or output. It sounds simple, but this alignment is often overlooked.
Touching on the burning topic of PFAS along with their health effects and environmental concerns, we learned that there are no non-stick pans in Andrew’s kitchen. For a moment the prototyping session turned into a cooking lesson, with a discussion of using the Leidenfrost effect to judge when stainless steel pans reach the ideal temperature for natural non-stick performance.
To close, Andrew walked us through a real decision-making process for a product in development. Starting with a high-cost brass part that defined the desired quality, they then tested a 3D-printed version that reduced cost but also performance. Ultimately a different technology that struck the right balance among cost, quality, and scalability was selected. This resulted in a product that could be manufactured affordably and at the right price point. That’s the sweet spot Andrew aims for: a strong product, a satisfied developer, and a happy customer.
It was great to have Andrew share his specialist knowledge with Hub members, tailoring his presentation to their needs and engaging deeply with the startup community’s questions. We look forward to continuing this series as a collaborative playground for physical product development - from prototyping to manufacturing.
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