{"id":14671,"date":"2025-12-05T21:11:09","date_gmt":"2025-12-05T20:11:09","guid":{"rendered":"https:\/\/prototal.info\/cases\/how-prototal-accelerated-sensorbees-products-with-hybrid-manufacturing\/"},"modified":"2026-04-28T15:09:26","modified_gmt":"2026-04-28T13:09:26","slug":"sensorbee","status":"publish","type":"case_studies","link":"https:\/\/prototal.info\/uk\/cases\/sensorbee\/","title":{"rendered":"How Prototal Accelerated Sensorbee\u2019s Products with Hybrid Manufacturing"},"content":{"rendered":"\n<p>Prototal partnered with Sensorbee, a Swedish developer of smart air-quality sensors, to accelerate product development using a hybrid manufacturing approach combining <a href=\"https:\/\/prototal.info\/uk\/services\/industrial-3d-printing\/\">industrial 3D printing<\/a> and <a href=\"https:\/\/prototal.info\/uk\/services\/injection-moulding\/\">injection moulding<\/a>. The result: faster time to market, improved durability, flexible production, and scalable growth. <\/p>\n\n<p><a href=\"https:\/\/www.sensorbee.com\/\">Sensorbee<\/a>, based in Link\u00f6ping, 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. <\/p>\n\n<h2 class=\"wp-block-heading\" id=\"headline-40-1193\">The Challenge: Fast Launch, Harsh Environments, and Scalable Production<\/h2>\n\n<p>Sensorbee needed a manufacturing partner who could help them launch a market-ready product that was:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Durable outdoors (UV, rain, heat, cold, and moisture)<\/li>\n\n\n\n<li>Adaptable to different applications and installation sites<\/li>\n\n\n\n<li>Fast to produce for early customer testing and revenue<\/li>\n\n\n\n<li>Cost-efficient at scale without sacrificing flexibility<\/li>\n<\/ul>\n\n<p>Traditional manufacturing alone couldn\u2019t meet these demands \u2014 especially within the required timeline.<\/p>\n\n<h2 class=\"wp-block-heading\" id=\"tw-target-text\">Prototal\u2019s Solution: A Hybrid Manufacturing Strategy (3DP + IM)<\/h2>\n\n<p>Prototal created a two-phase strategy using the strengths of both industrial 3D printing and injection moulding.<\/p>\n\n<div class=\"wp-block-media-text is-stacked-on-mobile\"><figure class=\"wp-block-media-text__media\"><img data-dominant-color=\"d1d4d6\" data-has-transparency=\"false\" style=\"--dominant-color: #d1d4d6;\" loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/prototal.info\/app\/uploads\/2025\/12\/sensorbee-complex-lid-1024x768.avif\" alt=\"\" class=\"wp-image-4719 size-full not-transparent\" srcset=\"https:\/\/prototal.info\/app\/uploads\/2025\/12\/sensorbee-complex-lid-1024x768.avif 1024w, https:\/\/prototal.info\/app\/uploads\/2025\/12\/sensorbee-complex-lid-300x225.avif 300w, https:\/\/prototal.info\/app\/uploads\/2025\/12\/sensorbee-complex-lid-768x576.avif 768w, https:\/\/prototal.info\/app\/uploads\/2025\/12\/sensorbee-complex-lid-1536x1152.avif 1536w, https:\/\/prototal.info\/app\/uploads\/2025\/12\/sensorbee-complex-lid.avif 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure><div class=\"wp-block-media-text__content\">\n<h4 class=\"wp-block-heading\"><strong><strong>Phase 1: Industrial 3D Printing for Rapid Market Entry<\/strong><\/strong><\/h4>\n\n\n\n<p>To accelerate testing and early production, Prototal 3D-printed the sensor\u2019s lid and base using advanced materials suitable for outdoor environments.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\"><strong><strong>What Industrial 3D Printing enabled:<\/strong><\/strong><\/h4>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Rapid prototyping and short production cycles<\/li>\n\n\n\n<li>Demand-driven manufacturing with minimal inventory<\/li>\n\n\n\n<li>Early customer feedback<strong> <\/strong>and revenue<\/li>\n\n\n\n<li>Design<strong> <\/strong>validation before committing to tooling<\/li>\n\n\n\n<li>Vapour smoothing for weatherproof, UV-resistant surfaces<\/li>\n<\/ul>\n<\/div><\/div>\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p><em>\u201cWe\u2019ve 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.\u201d<\/em><\/p>\n<\/blockquote>\n\n<h4 class=\"wp-block-heading\"><strong>Phase 2: Injection Moulding for High-Volume Scaling<\/strong><\/h4>\n\n<p>As demand grows, Sensorbee can seamlessly transition to in-house injection moulding at Prototal for the sensor base, reducing cost per unit.<\/p>\n\n<h4 class=\"wp-block-heading\"><strong>Key Benefits of Injection Moulding for Sensorbee:<\/strong><\/h4>\n\n<ul class=\"wp-block-list\">\n<li>Low unit costs at high volumes<\/li>\n\n\n\n<li>Stable, repeatable quality<\/li>\n\n\n\n<li>Fast turnaround for large-scale orders<\/li>\n<\/ul>\n\n<p>The caps, which require more complex geometries, will continue to be produced via AM. This ensures ongoing flexibility for design updates and customization. <\/p>\n\n<h2 class=\"wp-block-heading\" id=\"tw-target-text\"><strong>Results<\/strong><\/h2>\n\n<h4 class=\"wp-block-heading\"><strong>1. Faster Time to Market<\/strong><\/h4>\n\n<p>Sensorbee moved from prototype to production in weeks instead of months, giving them a critical first-mover advantage.<\/p>\n\n<h4 class=\"wp-block-heading\"><strong>2. Improved Product Performance<\/strong><\/h4>\n\n<p>AM and advanced finishing techniques enabled compact, waterproof, and sensor-tight enclosures\u2014difficult to produce with traditional methods.<\/p>\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p>\u201cWe are now doing things in very small spaces that were previously much larger \u2013 like shielding temperature sensors from solar radiation in a compact double-layer design.\u201d<br \/>\u2014 <strong>David L\u00f6wenbrand, Sensorbee<\/strong><\/p>\n<\/blockquote>\n\n<h4 class=\"wp-block-heading\"><strong>3. Cost-Effective Scaling<\/strong><\/h4>\n\n<p>Hybrid manufacturing allowed Sensorbee to start lean and scale efficiently:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Injection Moulding for low-cost, high-volume production<\/li>\n\n\n\n<li>Industrial 3D printing for flexibility and small batches<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\" id=\"tw-target-text\"><strong>Why Hybrid Manufacturing Can Work for You<\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li>Accelerated Prototyping &amp; Time to Market: Industrial 3D Printing enables rapid iterations, design freedom, and the production of complex parts \u2013 for both prototypes and production.<\/li>\n\n\n\n<li>Scalable Production: Injection Moulding lowers unit cost as volumes increase.<\/li>\n\n\n\n<li>Efficient Inventory: No need for large inventories thanks to fast, on-demand 3D printing.<\/li>\n\n\n\n<li>Design Flexibility: Customisation and modularity become effortless with industrial 3D printing.<\/li>\n\n\n\n<li>Reliable Performance: Vapor smoothing ensures tight enclosures for outdoor use.<\/li>\n<\/ul>\n\n<p>Together, Industrial 3D Printing and Injection Moulding offer speed, flexibility, and scalability\u2014a winning combination for modern hardware and product development.<\/p>\n\n<h3 class=\"wp-block-heading\" id=\"tw-target-text\"><strong>A Partnership Built for Growth<\/strong><\/h3>\n\n<p>Sensorbee\u2019s collaboration with Prototal demonstrates how a flexible manufacturing strategy can accelerate product development and create long-term competitive advantages. Prototal\u2019s ability to shift seamlessly between technologies ensures that Sensorbee can grow confidently\u2014from the first batch to high-volume production. <\/p>\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p><em>\u201cPrototal has been a fantastic partner. Their approach has helped us move quickly and maintain high quality \u2013 and we look forward to growing with them in the future.\u201d<\/em> <strong>\u2013 David L\u00f6wenbrand, CTO &amp; co-founder, Sensorbee<\/strong><\/p>\n<\/blockquote>\n\n<h3 class=\"wp-block-heading\" id=\"tw-target-text\">Let\u2019s Build Your Next Product Together<\/h3>\n\n<p>Whether you\u2019re launching a new hardware concept or scaling an established product, Prototal combines speed, scale, and flexibility\u2014all under one roof.<\/p>\n\n<p><a href=\"https:\/\/prototal.info\/uk\/contact\/\">Contact us today<\/a> to see how we can help support you on your next project!<\/p>\n","protected":false},"excerpt":{"rendered":"<p>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 moulding. The result: faster time to market, improved durability, flexible production, and scalable growth. Sensorbee, based in Link\u00f6ping, develops outdoor sensors for environmental monitoring that are used in smart [&hellip;]<\/p>\n","protected":false},"author":5,"featured_media":19690,"comment_status":"open","ping_status":"closed","template":"","categories":[175,95,97],"class_list":["post-14671","case_studies","type-case_studies","status-publish","has-post-thumbnail","hentry","category-electronic-applications","category-industrial-3d-printing","category-injection-molding"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>How Prototal Accelerated Sensorbee\u2019s Products with Hybrid Manufacturing | Prototal<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/prototal.info\/uk\/cases\/sensorbee\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"How Prototal Accelerated Sensorbee\u2019s Products with Hybrid Manufacturing | Prototal\" \/>\n<meta property=\"og:description\" content=\"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 moulding. 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