Industrial design is an essential part of successful product development and requires specialist knowledge of manufacturing processes such as injection moulding, 3D printing and CNC milling. For companies and developers new to the world of industrial design, it can be difficult to fully understand the differences and possibilities offered by these techniques.
In this blog, we discuss the key principles of industrial design and explain how various manufacturing processes work. This will give you a clear picture of the journey from idea to tangible product – from concept to mass production.
In formative manufacturing, raw materials are shaped into finished products using techniques such as injection moulding, thermoforming, rotational moulding and other moulding techniques. These manufacturing methods enable large-scale production at relatively low cost, particularly when compared to subtractive or additive manufacturing processes. A major advantage of formative manufacturing is that manufacturers can produce complex shapes and detailed components quickly and efficiently, without compromising on quality. This makes it a popular choice in sectors where precision and mass production converge.
However, this method does require specialised equipment and high-quality moulds, which entails a higher initial investment.
Injection moulding is a widely used manufacturing process in which molten plastic is injected into a mould under high pressure. This technique makes it possible to produce large numbers of identical products quickly and cost-effectively, ranging from small precision parts to large plastic housings. Thanks to its high precision and considerable design freedom, injection moulding is ideal for complex shapes and fine details, without compromising on quality or durability. The process is widely used in sectors such as consumer electronics, medical/lifestyle and mobility/infrastructure.
At GBO, we are constantly on the lookout for new production techniques that enable us to manufacture products more efficiently, more cost-effectively or to a higher standard. For (consumer) products requiring a high-quality finish in larger batches, plastic injection moulding remains a sound choice. The freedom of form combined with the wide variety of finishes makes this technique the most widely used production method. An additional advantage is the integration of structural elements with the design. Key considerations for injection moulding include: investment in any moulds, the expected batch size and the desired finish.
Rotational moulding (rotomoulding) is a moulding process in which plastic is heated inside a hollow mould and slowly rotated in multiple directions. This creates a seamless, hollow product with uniform wall thickness. This method is ideal for large, complex shapes such as tanks, containers and playground equipment. Rotational moulding is attractive due to its low moulding costs, great design freedom and the long service life of the products. GBO has a number of rotational moulding companies within its network and, together with these partners, we organise production for our client.
Thermoforming is a moulding production technique in which a plastic sheet is heated until it becomes sufficiently malleable and is then shaped into a mould using vacuum or pressure. This method is ideal for medium-sized production runs and relatively simple shapes, such as packaging, panels and displays. Thermoforming offers fast turnaround times, low set-up costs and is suitable for both prototypes and series production. GBO has a number of thermoforming companies within its network with whom we have been working for many years on behalf of various clients.
Subtractive manufacturing is a production process in which parts are formed by removing material from a larger workpiece. This is achieved using techniques such as milling, drilling, turning or other machining operations. This method is widely used for the manufacture of precision parts such as machine components and complex mechanisms. The major advantage of subtractive manufacturing is the high accuracy and tight tolerances that can be achieved.
As the process is often labour-intensive and relies on sophisticated, expensive machinery, production costs are generally higher than with formative techniques such as injection moulding. Nevertheless, subtractive manufacturing remains indispensable for applications involving metal or plastic where precision and dimensional stability are paramount.
Additive manufacturing, better known as 3D printing, is a manufacturing process in which an object is built up by applying layers of plastic, metal or other materials. This technique makes it possible to produce complex shapes, internal structures and bespoke components that are difficult or even impossible to achieve using traditional methods. Additive manufacturing is most commonly used for prototypes, small batches and customised products. Although the process generally takes longer than formative techniques such as injection moulding, it offers unrivalled design freedom, rapid iterations and minimal material waste. We are also seeing additive manufacturing increasingly used for large production runs or specific replacement parts in repairs.
An Original Equipment Manufacturer (OEM) is a specialised manufacturing facility that produces goods for other companies. OEM factories transform a product design into a tangible product of their own and often specialise in a single specific product type. They are used worldwide by both small and large companies.
Outsourcing production to an OEM factory offers companies the opportunity to benefit from expertise, economies of scale and cost savings. OEMs can mass-produce products faster, more efficiently and at lower cost than in-house production processes. Take, for example, television factories that manufacture television components exclusively for dozens of brands, significantly reducing production costs thanks to mass production and economies of scale.
Advantages of working with an OEM manufacturer:
Whether they are OEM factories abroad or regional manufacturing partners, they are available worldwide. Some of GBO’s clients operate their own factories, whilst others rely entirely on OEM partners for parts of their products.
At GBO Innovation makers, we carefully analyse which manufacturing process is best suited to each project during the industrial design process. This ensures we always achieve the optimal balance between quality, cost and efficiency. Most products consist of components manufactured using a variety of production techniques. Each type of production – from formative to subtractive and additive – has its own advantages and limitations, for both small batches and mass production.
Based on the product requirements, the moulding budget, the desired production costs and the expected production volumes, we recommend the most suitable production process for your design. We also help you find the right Original Equipment Manufacturer (OEM) specialising in the components you require. Thanks to our extensive global network of OEM partners, we ensure that your product is manufactured efficiently, cost-effectively and to the highest quality standards. We can therefore supply the complete product! Translated with DeepL.com (free version)
