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When it comes to luxury cars, every detail matters. Handles are no exception: they need to be lightweight, durable, and seamlessly integrated into the vehicle’s design and structure. In this project, we worked on the reinforcement handle, a crucial component that connects the handle’s mechanics to the car’s carbon fiber body. Our goal? To validate the initial design and bring it to final production with maximum precision.
The client provided a predefined design, and we got straight to work. To test the project’s feasibility, we created 10 prototypes (left and right) using Vacuum Casting, a technology that accurately replicates part details without the high costs and long lead times of industrial production. This phase was crucial in validating the design before moving on to mass production.
Dopo la fase di test, siamo passati alla produzione vera e propria. What we did:
🔸 We developed and manufactured the steel mold, ensuring durability and repeatability.
🔸 We injection-molded 80 parts (LH and RH) using our press, guaranteeing high performance and dimensional consistency.
🔸 We assembled the reinforcement handles, which were later bonded to the car’s carbon fiber body.
Beyond the reinforcement handles, we also produced the polyurethane buffer, a key component for the system’s functionality. But the most innovative aspect of this project was the 3D metal printing of the external handle part. This approach allowed for a lightweight yet incredibly strong piece, perfectly aligning with the demands of a high-performance vehicle.
Thanks to our expertise and technology, the client received a reliable, high-performance product ready for final vehicle assembly. This project showcases how the combination of rapid prototyping, injection molding, and 3D printing can make a real difference in the automotive sector.
