For a great deal of parts such as the steering wheel plate and the brake pot hanger, the only alternative to Robox would have been folded aluminium. Not only does this increase the chance of the parts being incorrect, but it would have cost around £150-£175 for the steering wheel plate, and £75-£100 for the brake pot hanger, both with a 2-week minimum lead time.
Contrasting with Robox, the steering wheel plate cost £2.66 and was ready to fit in just over 3 hours. The brake pot hanger cost £14 and took 10 hours to print, which again is much cheaper and faster than any alternative.
Additionally, we find that in many cases, 3D printed ABS parts are also more aesthetically pleasing than folded aluminium, and seem to suit the nature of our cars. For example, the switch box design would not have been possible in aluminium; it would have simply been a folded sheet with wires protruding out the back. Not only is there a safety aspect involved, but the ability to create a sealed box with all wires and connections hidden looks much better than a folded metal sheet. Again, this is achieved with costs being reduced from around £60 to £5.37.
For parts such as the rain light cover, the only alternative to Robox would be injection moulded plastic, or carbon fibre. Again, these options are unfeasible, as both would cost hundreds of pounds. With Robox, the component cost £2.95, and was complete in under 3 hours.
Most of the tooling we manufacture is used to remove wheel bearings, etc. These tools are usually fairly intricate and cost in the region of £300-£400. With a trial piece printed to test fits, usually for under £0.50, we can be sure that these tools will be correct.
Overall, in the past year I would make a conservative estimate that by using Robox, we have saved at least £3,000 and reclaimed around 2 months of lost build time in comparison to alternative methods.Tour De ForceMatt Scott, Design Engineer