Out-sider simplifies assembly and reduces weight with 3D printing
Lighter product and faster production
Measurable results
This is how much Out-Sider has saved
%
time
%
CO₂e
The challenge: Time-consuming assembly and complex inventory management
Out-Sider, a manufacturer of Scandinavian outdoor furniture, faced a challenge in assembling a key component in its product range. The component’s construction comprised as many as 12 individual parts in steel and rubber, which not only complicated logistics and inventory management, but also resulted in a manual, time-consuming assembly of 21 parts in total, including bolts.
This complexity led to:
- Higher labour costs.
- Increased risk of assembly errors and inconsistent quality.
- Limitations in flexibility and rapid delivery.
The solution: Consolidation and redesign via SLS 3D printing
By switching to 3D printing using SLS technology in PA12 nylon, the solution became both technically and functionally simpler. Out-sider redesigned the component so that 12 parts became just 3, and the entire assembly process could be significantly simplified.
The benefits were clear:
- Fewer parts, and therefore less need for inventory and easier handling.
- A lighter and stronger design optimised through mechanical testing.
- Less assembly work and higher precision.
Result: Lighter product and faster production
The switch to 3D printing reduced the total weight per unit by as much as 80%-from 1,864 g to just 360 g. Production runs can now be initiated down to a single unit (MOQ = 1), and lead time has been reduced from 14 to 10 days. Despite a slight increase in unit price (from EUR 53.5 to EUR 59), the overall economics have improved due to reduced manual effort and increased quality.
Results from programmes with Dansk AM Hub
- 80% weight reduction
- Lead time reduced from 14 to 10 days
- Overall economics improved, despite an increase in unit price
- 2.45 kg CO₂e saved in the manufacturing phase
The climate perspective: Halved CO₂ footprint
According to calculations using Danish AM Hub’s CO₂e calculator, the 3D-printed solution emits only 1.45 kg CO₂e per unit-compared with 2.99 kg CO₂e with conventional manufacturing. This corresponds to a reduction of more than 50% in global warming potential (GWP).
The contributions are distributed as follows:
- 2.45 kg CO₂e saved in the manufacturing phase.
- Lighter components also reduce the emissions burden during transport and over the product lifetime.
The future: Digitalisation and tailored solutions
Out-sider is now looking towards a fully digitalised inventory and local, on-demand production. Technologies such as topology optimisation and lightweighting open up even lower material consumption and tailored solutions at no additional cost.
3D printing has given Out-sider a lighter, stronger, and greener component-and an important step towards more agile and future-proof production.
About the company
Out-sider A/S
Location
Copenhagen
Number of employees
10
Info
Scandinavia’s leading supplier of urban furniture for public environments. Designed for active city life-for all ages and interests.
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