With SONIC, 5 vehicles (10 doors) are equipped per day.
24 vehicles are equipped per week.
104 vehicles are equipped per month.
1248 vehicles are equipped per year.
In the competitive mobility market, timing is everything. For innovative mobility companies, the high tooling costs and financial risks of traditional manufacturing methods can be barriers to quick market entry—especially for smaller production series. With SONIC machines, these companies gain a powerful advantage: the ability to bring end-use, fully customized vehicle parts at high-rate to market faster than ever, without mold expenses or extended lead times of conventional processes.
The Function-centric design approach allowed by AM, enables a "three-in-one" door solution that streamlines production and enhances part functionality. Each door is built with integrated storage compartments, a reinforced door handle, and embedded areas ready to accommodate windows, all crafted in a single manufacturing step. This eliminates the need for secondary processing or separate component assembly, reducing production times and minimizing complexity.
These end-use parts are manufactured from a high-added-value material, ensuring high durability and lightweight parts. The double-walled design provides both structural integrity and aesthetic flexibility, meeting rigorous standards for long-lasting performance while enabling companies to offer custom, design-specific products that meet consumer demands.
SONIC allows for quick digital-to-physical turnaround, facilitating rapid design modifications without any added cost or delay. Mobility companies can adjust designs on the fly, meeting unique customer preferences and brand-specific requirements in a fraction of the time. The result is an agile, low-risk approach to vehicle component production, empowering companies to quickly access the market with a finished product that reflects their brand and satisfies consumer demand.
Thanks to FGF (Fused Granular Fabrication), mobility manufacturers can keep using the same high-performance materials they rely on for decades in Automotive field, ensuring continuity in material quality and compliance. The door was produced with an Automotive Injection Grade (Recyclable) Polypropylene reinforced with Glass Fibers. Polypropylene gives elastic properties to the door, while fibers strengthen the material in the core, minimizing the heterogeneous phenomenon caused by layer deposition.
Here, we observe how smooth the storage compartment was built-in the door. Bonded in core, we obtain as a result a cohesive mechanical behavior between the storage feature and the door. Also, the precision of deposition allows to produce the border of window frames within the part. This gives a major advantage, facilitating the post-processing by eliminating the need to mill an embedded zone. The outline is already designed for the integration of the window frame.
The door was printed within two adjacent shells for mechanical reasons. In the prototyping phase, it was observed that one shell was enough for standard use; nevertheless, in order to prioritize strength, we opted for this enhanced double-shelled solution, longer to produce but more robust. As a result, we obtain a durable and strong door. Knowing this, we note that there is an important leverage remaining on optimizing the production rate and the weight of the part.
SONIC redefines Mobility Manufacturing. It's advanced capabilities make it an ideal choice for companies looking to lead the way in mobility innovation. By enabling design flexibility, our clients gain a streamlined path to market for their small-scale, customizable vehicle solutions. This vehicle door demonstrates the power of High-Speed LSAM in the mobility sector : an end-use, fully integrated part that brings value through speed, functionality, and seamless design integration.
