With SONIC, 4 Road Compactor is equipped per day.
20 Road Compactor is equipped per week.
90 Road Compactor is equipped per month.
1073 Road Compactor is equipped per year.
In the heavy construction machinery sector, producing components like the front cover for road compactors faces a core challenge: low production volumes. Traditional methods, such as injection molding, entail significant tooling costs that can be difficult to amortize when production runs are under 2,000 units per year. For manufacturers in this industry, these high upfront expenses make it challenging to justify investing in molds, especially as part designs evolve and require multiple iterations over time. LINES SONIC’s added value directly addresses this issue, offering a tooling-free manufacturing solution tailored to the low- and mid-volume demands typical in heavy machinery projects.
SONIC streamlines the production process, enabling manufacturers to move directly from digital design to full-scale production. This tooling-free approach not only reduces initial costs but also shortens lead times, providing manufacturers with quicker access to market and the ability to rapidly adapt designs without being tied to fixed molds.
The front cover is crafted from a high-strength injection grade polycarbonate reinforced with glass fiber, coming from our Early-tester’s portfolio of qualified material. Their material, after qualification with Lines’ extrusion process, was used for crafting their front covers. This material ensures robustness, durability, and weight efficiency in demanding road environments.
SONIC’s advanced manufacturing also easily allows for localized reinforcement: the front panel around the headlights is intelligently filled to withstand mechanical loads, offering added resilience in impact-prone areas. This optimization minimizes material waste while enhancing functional performance.
The other interesting point with this infill reinforcement is to create a zone where headlights could be easily implemented by embedding the headlights components (electric cables) inside the part (infill zone). This illustrates also one of the most intelligent assets of AM : only put material where it's needed.
SONIC’s function-centric design approach integrates essential features, like handling grips, directly into the part, reducing additional component needs and minimizing assembly times. This flexibility enables seamless part adjustments throughout production, supporting on-demand customizations without extra costs or delays. Exhaust air grid zones are also prepared in the initial design with an outlined section that is printed within the part, ready to be cut after production before grid assembly. The integration of specific functional attributes directly into the design allows customers to come as close as possible to a finished product.
To meet the aesthetic demands of the heavy equipment industry, the parts received a high-quality automotive finish. This treatment ensures that the cover meets exterior appearance standards. From the outside, the Hood cannot be recognized as an Additive Manufacturing product, showcasing the high level of quality achievable with the SONIC machine.
SONIC redefines how components like front covers are produced in the road equipment industry. Tooling-free production, efficient material use, and expansive design flexibility enable manufacturers to meet the functional and economic demands of their projects. This case illustrates how AM with SONIC produces a durable, custom-built front cover—driving down costs, accelerating production, and setting a new standard in the heavy machinery sector.
