Challenge and solution

Challenge

Challenge

When working on the BOSEbuild Headphones the BOSEbuild design and engineering team needed to prototype the yolk, a vital part of the headphones that attaches ear pucks to the headband. Although they initially used the BOSE prototyping service to create their master part, they realized there was a dire need for more than one yolk to facilitate further product testing. Additionally, it was essential that the headphones looked and felt like the desired end product, with each part working seamlessly together.

Solution

Solution

Having two Ultimaker printers on hand allows for greater flexibility in BOSEbuild design projects. In the case of BOSEbuild Headphones, they were able to produce several yolks in various colors. The yolks were flexible enough to survive testing by the App Team, Firmware Team, and Acoustics Team—all of which meant early developers were up and running faster for prototype production and design approval. By saving time and money with Ultimaker, they are able to focus on results to perfect the end product.

Cost comparison

In-house Ultimaker 3D printers

Outsourcing

Costs per iteration $1-2 Costs per iteration $30-$40
Time per iteration 3 hours Time per iteration 3 days

BOSEbuild Principal Project Engineer Darius Mobed states, “Quickly printing flexible, adaptable prototypes that survive product testing enables early developers to get everything up and running.”

Results

Usability testing

Usability testing

Producing parts for functional prototypes means the BOSEbuild team no longer had to wait between iterations to test product usability.

3D printing functional prototypes
Acoustics tuning

Acoustics tuning

Early acoustics tuning using a dummy head was essential for the BOSEbuild Headphones, and made possible by the yolk produced on an Ultimaker.

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Marketing research

Marketing research

Wearable prototypes with parts printed on Ultimaker facilitated early marketing research that fine-tuned their approach for the end product.

3D printing in product design
Product feedback

Product feedback

With fully functional early prototypes on hand, the BOSEbuild team was able to test the product on their target audience for immediate product feedback.

3D printing in concept models

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