- Case Studies
- Muller Case Study: Manufacturing a Stylish POS Cover
Muller Case Study: Manufacturing a Stylish POS Cover
- Star Rapid
- 3 min
- Case Studies
- Muller Case Study
Muller Case Study: Manufacturing a Stylish POS Cover
“We are constantly researching the market for suppliers that can provide quality products that meet our clients’ requirements. Having thoroughly researched the company and spoken with its technical staff we were impressed with the skill level, technical know-how and range of products it has produced for its customers. The finished prototype met our specifications exactly, and they were delivered on time and within budget. We will certainly be using Star Rapid again.”
Prototyping a Clearly Beautiful POS Fascia
A good point-of-sale (POS) terminal solves the most common daily retail challenges. It increases checkout speed, accommodates a variety of payment methods, and allows staff to conduct transactions anywhere. It’s a bonus if it also looks good and features unique design elements, like the transparent case we helped Muller Commercial Solutions test on the market.
The Challenge: Balancing Budget and Beauty
The two main challenges of this project rang true for many rapid prototyping initiatives:
- Balancing cost-efficiency with high-quality outputs
- Choosing the appropriate prototyping techniques to match the product’s requirements
Meeting these demands required precise planning and technical know-how to choose the most efficient production methods. We needed state-of-the-art facilities equipped with cutting-edge machinery and skilled professionals to operate them.
CNC machining was chosen as the fastest and most precise method to fabricate the parts. And vapor polishing helped us achieve the total transparency the design required.
We chose to work with polycarbonate (PC) because it offers the combination of optical clarity, impact resistance, and durability required to create these robust and transparent covers.
Our Approach: Making Transparent Covers Polished to Perfection
Our production process is simple, yet effective:
- Material Identification
- Design File Review
- Cutting PC Blocks
- Hand Polishing
- Vapor Polishing
- Inspection
Some of these processes are standard at Star Rapid. We perform Positive Material Identification (PMI) on every project to verify the chemical composition of each incoming material. This ensures safety during production and assures our clients of the quality and performance of the products.
We also carefully analyze design files before starting every project to ensure we understand the function of the parts and the fine details of their features. Next, we created cutting programs based on the 3D CAD data sent by the client. Our engineers and operators set various CNC machine parameters, such as speed and feed rates.
They also selected the best cutting tools and toolpaths to cut each part of the cover from a solid block of polycarbonate securely mounted on the machine. Then, it was time to prepare the surface for finishing.
Applying Vapor Polishing
Since the covers needed to be completely transparent, they were hand-sanded up to 1000 grit. Vapor polishing works at the molecular level, so the result would be less than optimal if there were deeper scratches or machine marks on the part’s surface.
Vapor polishing is a technique that uses Weldon4 gas heated to 43° C in a controlled environment. The gas vapor reacts with the plastic at the molecular level to cause it to partially melt and smooth out to optical clarity.
The success of this complex operation depends on skilled workmanship and an atmospherically sealed chamber. It requires safety equipment such as breathing respirators, and the team is supported by additional personnel outside the chamber.
After the application, the parts were sent to our inspection department. There, experts measured every detail and compared them with the design files sent by the client. This level of detail is standard to help us verify the quality of each part that leaves our factory.
The Result: Prototypes Ready in Just 10 Days
- The appropriate choice of manufacturing methods
- Facilities, machinery, and a qualified team to execute each technique
- Project management and robust supply chain optimized for rapid prototyping
We were able to make them faster and more affordably. If you are developing a new product, it’s crucial to partner with manufacturers who bring this level of experience to your project. They should do more than just execute manufacturing methods—they should be able to present the best options to you and optimize each step.
Bring Your Product Vision to Life
When it comes to building parts with precision and quality, Star Rapid is the ideal partner. We have decades of experience creating functional prototypes that are aesthetically appealing in short time frames and at affordable prices.
Whether you’re developing a proof of concept, creating initial units, or bridging to full production, your parts will always be made to the highest standards.
Upload your CAD files now, and let’s discuss the best approach to bringing your product to life.
