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AEG/Robert Hoffman Modellbau GmbH
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Stereolithography prototypes allow AEG Hausgeräte to apply concurrent engineering and,
subsequently, to halve the company's typical product-development time.
"We could not have carried out a project like this without SL prototypes.
They help us save time and, above all, costs for our customers."
- Robert Hofmann, President
Robert Hofmann Modellbau GmbH
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The Challenge
Design engineers at AEG Hausgeräte were assigned the arduous task of bringing a completely new
vacuum cleaner to market in just 13 months. Given the latest consumer information, designers were
to apply this knowledge to develop a competitive product in half the time of their usual
development time frame of 2.5 years. Missing the deadline could cost the company its share in the
aggressive vacuum cleaner market.
The 13 month time frame would encompass the entire design of the product, prototyping and
manufacturing of initial shipments. Furthermore, the new "Yallo" vacuum cleaner design had to
prove reliable and robust.
The Results
AEG Hausgeräte turned to Robert Hofmann Modellbau GmbH and Hofmann Wekzeugbau and that group's
stereolithography expertise to meet its tight deadline. In 140 hours, AEG had SLA prototypes from
which its designers could analyze form, fit up and assembly of components. Digitized surface data
taken from a foam model of the vacuum cleaner allowed Hofmann engineers to create a 3-dimensional CAD solid
model of the vacuum cleaner. A master pattern, milled using the initial CAD model, was a base from
which AEG engineers designed the components. Hofmann engineers quickly created prototypes of all
components using stereolithography.
The SLA prototypes proved useful in analyzing assembly of the components, allowing fine-tuning
of the primary CAD model and quick building of iterative SLA prototypes. The SLA prototypes also
verified tooling designs that would meet production molding demands. AEG easily met its deadline,
turning out an easy-to-produce and accurately assembled vacuum cleaner in just 13 months. SLA
technology allows AEG Hausgeräte to:
- Cut product development time by 56%
- Identify flaws in fit-up not visible in 3-dimensional CAD models
- Optimize design criteria before building hard tooling
- Evaluate form and fit of all components
- Save DM 30,000, nearly U.S. $20,000, in tool development costs
The Process
Design engineers at AEG Hausgeräte used initial design ideas to create a foam model of its new
vacuum cleaner. Digitizing the foam model using EDS Unigraphics and CATIA software, designers at
Robert Hofmann Modellbau created a solid-CAD model that provided NC milling information to machine
a master pattern.
Engineers from AEG, Hofmann Modellbau and Hofmann Werkzeugbau used the master to verify the
surface data as well as check the aesthetic design of the product.
The master pattern became a foundation upon which engineers designed the 15 components that make
up the vacuum cleaner. These components included upper and lower shell halves, controls, handle
parts, buttons, cable roller, micro-filter trim, vacuum cleaner cover, latches and fan cup.
Downloading the 3-dimensional CAD model for each component to an SLA 500 stereolithography machine at
Hofmann Modellbau, AEG was able to obtain prototypes based on its initial design in only 140
hours.
The fit-up of these components, especially the fan cup, was critical.
The SLA prototypes, which held tolerances of 0.05 mm, allowed designers
to test form and fit of the components. Assembly of the prototypes revealed
design flaws not detected in the 3-dimensional CAD model. Modifications
to the CAD model were quickly turned into SLA prototypes, allowing designers
to fine-tune component design before building any hard mold-making tooling.
AEG Hausgeräte, using SLA prototypes, applied concurrent engineering to
successfully introduce its new "Yallo" vacuum cleaner in just 13 months.
The Tools
- EDS Unigraphics software, version 10
- CATIA software
- SLA 500 with CIBATOOL SL 5180 resin
Company Profile
AEG Hausgeräte, headquartered in Nuremburg, Germany, is a leading manufacturer of consumer
products. Employing 9,000 people worldwide, AEG manufactures washing machines, vacuum cleaners,
fabric-care appliances, coffee makers and other consumer products.
Robert Hofmann Modellbau is a rapid-development service provider offering comprehensive
design, production tooling, rapid tooling and prototyping, tooling design and NC data generation.
Hofmann primarily serves the auto industry and its vendors. The company also serves the
household-appliance, consumer-products, toy, ceramic and computer industries.
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