At Prototal, innovation is not just something we talk about – it is built into everything we do. Additive Manufacturing (AM) transforms the possibilities of design and production.
And when AM is combined with Injection Moulding (IM), the results can change whole approaches to manufacturing. That is exactly what happened in our collaboration with Sensorbee, a Swedish pioneer in smart, solar-powered air quality sensors.
About Sensorbee: Smart Tech for a Cleaner Tomorrow
Sensorbee, based in Linköping, Sweden, develops outdoor environmental sensors used in smart cities, construction sites, harbours, and industrial areas. These compact, solar-powered units connect via cellular networks and transmit real-time data to a cloud platform, enabling data-driven decisions to reduce air pollution.
“Our mission is to improve the world by deploying more sensor technology that can create insights into outdoor air quality. We make it simple – no external power, just a solar panel, plug it in, and it starts reporting."
– David Löwenbrand, CTO and Co-founder, Sensorbee
Their latest sensor unit represents the third generation of development – a product composed by learning, iteration, and innovation.
Sensorbee’s Challenge: Speed, Scale, and Environmental Demands
Sensorbee needed to move quickly with a product that was:
- Market-ready for early revenue and feedback,
- Built to withstand outdoor exposure (UV, rain, temperature swings),
- Customisable based on use case and location,
- Scalable for mass production with tight cost controls.
These requirements led to the conclusions that taditional manufacturing alone was not enough. That’s where Prototal stepped in.
The Solution: A Hybrid Manufacturing Approach
We collaborated closely with Sensorbee to develop a manufacturing strategy that suited their particular needs. And it resulted in a combination of the best of two worlds, Additive Manufacturing and Injection Moulding:
Rapid Start with AM
We began by 3D printing the lid and base of the enclosure using advanced materials and vapor smoothing for post-processing of the surfaces to create weatherproof and UV-resistant product parts.
This enabled Sensorbee to:
- Begin customer trials rapidly
- Validate design and function, and
- Generate early revenue
- Run their business with on-demand production
“Before, 3D printing was a limitation, when aiming for high-quality product parts. With Prototal’s offer, including vapor smoothing and durable materials, we could go straight to parts performing just as we needed them to.”
– David Löwenbrand, Sensorbee
Transition to IM for Scalability
Once Sensorbee wants to scale to much higher production volumes, they can swiftly shift the production of the base component to injection moulding, in-house at Prototal, reducing per-unit costs and supporting higher volumes. The lids, however, with their complex geometries, will continue to be 3D printed, giving Sensorbee ongoing flexibility to update designs and customise configurations.
“We’ve been able to keep batch sizes small, get fast deliveries, and avoid large inventories. That flexibility has really helped to keep our costs at reasonable levels.”
– David Löwenbrand, Sensorbee
Results: A Compact Powerhouse
Faster Time-to-Market
Industrial 3D printing allowed Sensorbee to go from prototype to peoduction in weeks, instead of months.
Enhanced Product Design
Additive Manufacturing and post-processing enabled compact, watertight, sensor-rich devices that would have been hard or impossible to produce with conventional means.
“We’re doing things in very small spaces now that used to be much bulkier – like shielding temperature sensors from solar interference in a compact double-layer design."
– David Löwenbrand, Sensorbee
Cost-Effective Scaling
Injection moulding will in the future ensure low cost per unit at scale, while AM remains the best choice for customised and complex parts.
Why Hybrid Manufacturing Could Also Work for You
- Accelerated Prototyping & Launch: AM enables fast iterations, design freedom and production of complex parts, both for prototypes, and full-scale production.
- Scalable Production: IM reduces unit costs once volumes grow.
- Inventory Efficiency: No need for large stocks thanks to fast, on-demand 3D printing.
- Design Agility: Customisation and modularity are seamless with AM.
- Reliable Performance: Vapor smoothing ensures watertight seals for outdoor use.
A Partnership Built for Growth
Sensorbee’s collaboration with Prototal shows how the choice of right manufacturing methods lead to smarter, faster product development. With our capacity to seamlessly transition between technologies, and quickly adapt to your needs, we are your partner for the production from one to one million product parts.
“Prototal has been a great partner. Their approach has helped us move quickly and keep quality high – and we’re excited to grow with them in the years ahead.”
– David Löwenbrand, CTO and Co-founder, Sensorbee
Ready to Explore Manufacturing with Prototal?
Let’s talk. Whether you're launching a startup device or optimising a high-volume product, Prototal brings together speed, scale, and flexibility – all under one roof.
