How Done Lab is Transforming Production in the Automotive Industry
Done Lab: Additive Manufacturing for Advanced Tooling and Jigs
Done Lab is now one of the leading international references in applied research in additive manufacturing. Founded in 2016, the laboratory specializes in the development of prototypes, short-series products, customized tools, combining academic and industrial innovation.
The Challenge
To accelerate development processes and ensure high performance, Done Lab needs:
Rapid validation of functional prototypes
Reduce prototyping time compared to traditional processes to rapidly test parts in real conditions.
High-performance materials
Solutions capable of offering high strength, advanced fiber control, precision, electromagnetic compatibility, and design freedom.
Scalable and flexible production of end-use parts
Increased build volume and reduced lead times without compromising quality.
The Requirement: Developing an Electronic Enclosure with Electromagnetic Shielding
As part of the SIFA – Smart System for Additive Manufacturing project, Done Lab was tasked with redesigning an electronic enclosure for a Bosch digital display system for motorcycles.
The new solution needed to:
- Protect internal components (PCB, display, connectors);
- Ensure compliance with electromagnetic compatibility standards (CISPR 25);
- Reduce costs and lead times compared to CNC machining and injection molding.
The Solution
Done Lab has identified the Digital Forge platform as the most effective technical solution, leveraging the expertise and consultancy of 3DZ, a trusted Markforged partner.
Key Benefits:
- Use of technical composite materials such as Onyx™ reinforced with continuous carbon fiber delivering metal-like strength.
- High-quality surface finish with no post-processing required.
- Optimized design with internal ribs for added strength and inclined walls to minimize support usage.
The FX20™, the latest machine added to the lab further expanded the production capabilities of Done Lab who was already using the Mark Two™, enabling the fabrication of large, high-performance engineering components.
Specifically, regarding the electromagnetically shielded electronic enclosure, the component redesign and the shift to advanced polymer materials — Onyx™ reinforced with long carbon fiber — allowed Done Lab to achieve concrete results:
- EMC compliance (CISPR 25): the new enclosure provides effective electromagnetic shielding in line with automotive standards.
- Reduced costs and lead times: the lab eliminated the need for molds, accelerating development and lowering expenses.
- End-use functionality: the component meets both mechanical and electromagnetic requirements of the digital display system.
“The results were convincing, meeting the levels required by automotive electromagnetic compatibility standards such as CISPR 25. This outcome not only validates 3D printing for functional prototypes but also for the production of final parts, as demonstrated by the specific case of the motorcycle display system.”
— Catia Silva, Polymer and Composites Engineer at Done Lab
The Future
The positive experience has led Done Lab to plan further investments, with the goal of expanding its production capacity.
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