Hobbs ATV Headlamp system

Problem/Challenge Bridge Production
High Intensity Discharge (HID) headlights provide auto-makers with more design options and more illumination than conventional halogen headlights. They also generate over twice the heat, making conventional prototypes useless for functional testing. This is just what faced Hobbs, a global supplier of engineered products, when developing their new ATV Headlamp System.

Solutions/Results Rapid Tooling
Conventional cut aluminum tooling would take too long, therefore General Pattern’s Rapid Hybrid Tooling was selected. By combining the disaplines of high speed milling and laser sintering over 250 sets of parts from 8 injection molds were produced in 3 weeks.

Benefit/Impact Injection Moulding
Honda was able to meet their prototype requirements with timing, cost and quality that surpassed even their expectations! Unaware they were competing with another industry lighting leader, Hobbs won the contract to supply Honda… they were awarded the contract because they were the first to market; providing quality product on time and at a responsible cost.

Commercial
Price $79,000 (12 tools)
Performance 2 weeks (tools were completed and 100 sets of parts delivered).