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Case Study

Accelerating Product Development with Rapid Prototyping

  • Client Challenges

A leading heavy equipment manufacturer was developing a new hydraulic system component for use in construction and mining machinery. The company encountered several challenges:

  • High development costs, as traditional prototyping methods were expensive.
  • Extended lead times, delaying field testing and final production.
  • Strict durability requirements, as the component had to withstand high pressure, extreme temperatures, and heavy loads.
  • Complex geometry, making it difficult to manufacture and test multiple design iterations quickly.

The company needed a trusted prototyping partner to produce functional, high-precision prototypes for validation before mass production.

  • Stamod’s Solution

Stamod provided a cost-effective, high-precision prototyping solution, using a mix of traditional and advanced manufacturing techniques to meet the client’s demands:

  • Hybrid Prototyping Approach – Combining CNC machining, metal 3D printing, and injection molding for accurate, durable prototypes.
  • High-Strength Material Selection – Using heat-resistant alloys and reinforced polymers for enhanced durability.
  • Rapid Iterative Prototyping – Allowing multiple design adjustments based on real-world performance feedback.
  • Scalability for Production – Ensuring the prototype was optimized for seamless large-scale manufacturing.
  • Implementation Process
  1. Material & Design Feasibility Study – Selecting high-strength metals and polymers suitable for heavy-load applications.
  2. Prototype Fabrication & Initial Testing – Producing a CNC-machined metal prototype for stress and endurance testing.
  3. Iterative Refinement & Load Testing – Adjusting the design to optimize structural integrity and efficiency.
  4. Production Readiness & Cost Optimization – Finalizing a scalable, cost-effective manufacturing process.

40% faster prototype development, reducing product launch delays.

25% cost savings, optimizing the company’s R&D budget.

Higher durability, ensuring the component met performance expectations in harsh operating conditions.

Smooth transition from prototype to production, eliminating last-minute design modifications.

Offshore Engineering Design Support

  • Client Challenges

A leading EV components manufacturer was facing several engineering design challenges that were slowing down production and increasing costs:

  • High design and development costs, affecting product profitability.
  • Shortage of skilled engineers, making it difficult to scale operations.
  • Stringent industry standards (ISO 26262, ASIL, SAE J1772, etc.), requiring precise, regulation-compliant designs.
  • Need for rapid prototyping and design modifications, to keep pace with the fast-evolving EV industry.

To overcome these hurdles, the company sought an offshore engineering design partner that could provide cost-effective, high-quality design support while ensuring compliance with automotive safety regulations.

  • Stamod’s Solution

Stamod provided a dedicated offshore engineering team, seamlessly integrating with the client’s internal R&D division. The approach included:

  • Dedicated Offshore Engineering Team – Experienced automotive design engineers specializing in battery enclosures, thermal management, and lightweight materials.
  • Advanced 3D Modeling & FEA Simulations – Utilizing CATIA, Siemens NX, and ANSYS for detailed component design and stress analysis.
  • Rapid Design Iterations & Prototyping Support – Enabling quick modifications based on aerodynamic testing and real-world simulations.
  • Regulatory Compliance Assistance – Ensuring all designs met ISO 26262 (functional safety), SAE standards, and crash safety regulations.
  • Implementation Process
  1. Project Scoping & Team Deployment – Understanding client requirements and assembling a dedicated EV engineering design team.
  2. Seamless Collaboration & Workflow Integration – Aligning Stamod’s engineers with the client’s design validation and testing processes.
  3. Iterative Design Modifications – Implementing lightweight material optimizations and thermal efficiency improvements based on client feedback.
  4. Final Validation & Compliance Check – Ensuring production-ready designs met safety and performance benchmarks.

30% reduction in engineering design costs, improving overall product margins.

50% faster turnaround times, enabling the client to accelerate EV component development.

Improved design accuracy and compliance, ensuring seamless regulatory approvals

Scalable offshore support, allowing the client to expand design capacity without additional hiring.

Manufacturing Support for Plastic Injection Molded Part

  • Client Challenges

A leading manufacturer of consumer electronics accessories faced several production challenges related to their plastic injection molding operations:

  • High material wastage, increasing production costs and reducing profitability.
  • Inconsistent part quality, leading to high rejection rates from customers.
  • Production bottlenecks, causing delays in fulfilling large-volume orders.
  • Need for advanced tooling and process optimization, to meet growing market demand.

The company required a manufacturing support partner to optimize injection molding processes, reduce defects, and improve production efficiency.

  • Stamod’s Solution

Stamod provided end-to-end manufacturing support to improve plastic injection molding efficiency and product quality. Our approach included:

  • Process Optimization & Cycle Time Reduction – Implementing scientific molding techniques to reduce cycle times and enhance part consistency.
  • Material Efficiency Improvements – Introducing advanced material flow analysis to minimize waste and optimize raw material usage.
  • Quality Control & Defect Reduction – Utilizing automated inspection and real-time monitoring systems to identify and correct defects early in the production process.
  • Tooling & Mold Design Enhancements – Refining mold designs and cooling channel layouts for better part precision and durability.
  • Implementation Process

Stamod provided end-to-end manufacturing support to improve plastic injection molding efficiency and product quality. Our approach included:

  • Process Optimization & Cycle Time Reduction – Implementing scientific molding techniques to reduce cycle times and enhance part consistency.
  • Material Efficiency Improvements – Introducing advanced material flow analysis to minimize waste and optimize raw material usage.
  • Quality Control & Defect Reduction – Utilizing automated inspection and real-time monitoring systems to identify and correct defects early in the production process.
  • Tooling & Mold Design Enhancements – Refining mold designs and cooling channel layouts for better part precision and durability.

20% reduction in material waste, leading to significant cost savings.

30% improvement in production efficiency, enabling the client to meet high-volume demands.

30% improvement in production efficiency, enabling the client to meet high-volume demands.

Improved lead times, allowing the client to fulfill orders faster and strengthen customer relationships

AI-Driven Manufacturing Optimization for an FMCG Company

  • Client Challenges

A leading FMCG manufacturer producing personal care and household products faced multiple operational inefficiencies, including:

  • Fluctuating consumer demand, leading to frequent stockouts or excess inventory.
  • Inefficient production scheduling, causing delays in order fulfillment and higher operational costs.
  • Supply chain disruptions, affecting the availability of raw materials and impacting production timelines.
  • High waste generation, as overproduction and quality control issues led to excessive material losses.

To stay competitive, the company needed an AI-powered solution to optimize demand forecasting, streamline production, and improve supply chain resilience.

  • Stamod’s Solution

Stamod implemented a custom AI solution designed to enhance demand forecasting and production planning. Our approach included:

  • AI-Powered Demand Forecasting – Using machine learning models to analyze historical sales data, seasonal trends, and market dynamics, enabling accurate demand predictions.
  • Automated Production Planning – Leveraging AI-driven insights to align production schedules with real-time demand, reducing excess stock and shortages.
  • Supply Chain Optimization – Implementing predictive analytics to identify potential supply chain risks and optimize raw material procurement.
  • Waste Reduction & Quality Control – Using computer vision and AI algorithms to minimize material waste and enhance product quality consistency.
  • Implementation Process
  1. Data Collection & AI Model Training – Integrating historical sales, supply chain, and production data into a centralized AI platform.
  2. Real-Time Demand Forecasting Deployment – Implementing AI-driven forecasting tools to predict consumer demand fluctuations with high accuracy.
  3. Production & Inventory Optimization – Automating just-in-time production scheduling based on AI-driven demand forecasts.
  4. Continuous Monitoring & Refinement – Using AI feedback loops to improve forecasting accuracy and production efficiency over time.

20% improvement in demand forecasting accuracy, leading to optimized inventory levels.

5% reduction in production costs, by aligning manufacturing schedules with real-time demand.

30% reduction in material waste, through AI-powered quality control and waste minimization strategies.

Faster order fulfillment, ensuring products were available at the right time in retail distribution channels.

STAMOD works seamlessly with clients in three different models, with embedded staff on the client’s OEM customer locations doing product development and design. An onsite model works in customer locations and provides offshore services in India.
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