Prototal partnered with Sensorbee, a Swedish developer of smart air-quality sensors, to accelerate product development using a hybrid manufacturing approach combining industrial 3D printing and injection molding. The result: faster time to market, improved durability, flexible production, and scalable growth.
Sensorbee, based in Linköping, develops outdoor sensors for environmental monitoring that are used in smart cities, construction sites, ports and industrial areas. Their devices transmit real-time environmental data via mobile networks, allowing organisations to make data-driven decisions to reduce pollution.The product featured in this case is their third-generation sensor, built on years of iteration and customer feedback.
The Challenge: Fast Launch, Harsh Environments, and Scalable Production
Sensorbee needed a manufacturing partner who could help them launch a market-ready product that was:
- Durable outdoors (UV, rain, heat, cold, and moisture)
- Adaptable to different applications and installation sites
- Fast to produce for early customer testing and revenue
- Cost-efficient at scale without sacrificing flexibility
Traditional manufacturing alone couldn’t meet these demands — especially within the required timeline.
Prototal’s Solution: A Hybrid Manufacturing Strategy (3DP + IM)
Prototal created a two-phase strategy using the strengths of both industrial 3D printing and injection moulding.
Phase 1: Industrial 3D Printing for Rapid Market Entry
To accelerate testing and early production, Prototal 3D-printed the sensor’s lid and base using advanced materials suitable for outdoor environments.
What Industrial 3D Printing enabled:
- Rapid prototyping and short production cycles
- Demand-driven manufacturing with minimal inventory
- Early customer feedback and revenue
- Design validation before committing to tooling
- Vapour smoothing for weatherproof, UV-resistant surfaces
“We’ve been able to keep batch sizes small, get fast deliveries, and avoid large inventories. That flexibility has really helped us keep costs at reasonable levels.”
Phase 2: Injection Moulding for High-Volume Scaling
As demand grows, Sensorbee can seamlessly transition to in-house injection moulding at Prototal for the sensor base, reducing cost per unit.
Key Benefits of Injection Molding for Sensorbee:
- Low unit costs at high volumes
- Stable, repeatable quality
- Fast turnaround for large-scale orders
The caps, which require more complex geometries, will continue to be produced via AM. This ensures ongoing flexibility for design updates and customization.
Results
1. Faster Time to Market
Sensorbee moved from prototype to production in weeks instead of months, giving them a critical first-mover advantage.
2. Improved Product Performance
AM and advanced finishing techniques enabled compact, waterproof, and sensor-tight enclosures—difficult to produce with traditional methods.
“We are now doing things in very small spaces that were previously much larger – like shielding temperature sensors from solar radiation in a compact double-layer design.”
— David Löwenbrand, Sensorbee
3. Cost-Effective Scaling
Hybrid manufacturing allowed Sensorbee to start lean and scale efficiently:
- Injection Molding for low-cost, high-volume production
- Industrial 3D printing for flexibility and small batches
Why Hybrid Manufacturing Can Work for You
- Accelerated Prototyping & Time to Market: Industrial 3D Printing enables rapid iterations, design freedom, and the production of complex parts – for both prototypes and production.
- Scalable Production: Injection Moulding lowers unit cost as volumes increase.
- Efficient Inventory: No need for large inventories thanks to fast, on-demand 3D printing.
- Design Flexibility: Customization and modularity become effortless with industrial 3D printing.
- Reliable Performance: Vapor smoothing ensures tight enclosures for outdoor use.
Together, Industrial 3D Printing and Injection Moulding offer speed, flexibility, and scalability—a winning combination for modern hardware and product development.
A Partnership Built for Growth
Sensorbee’s collaboration with Prototal demonstrates how a flexible manufacturing strategy can accelerate product development and create long-term competitive advantages. Prototal’s ability to shift seamlessly between technologies ensures that Sensorbee can grow confidently—from the first batch to high-volume production.
“Prototal has been a fantastic partner. Their approach has helped us move quickly and maintain high quality – and we look forward to growing with them in the future.” – David Löwenbrand, CTO & co-founder, Sensorbee
Let’s Build Your Next Product Together
Whether you’re launching a new hardware concept or scaling an established product, Prototal combines speed, scale, and flexibility—all under one roof.
Contact us today to see how we can help support you on your next project!
