Home >> Case Studies >> Bosch Lawn & Garden - Functional prototypes cut development time for Bosch

Bosch Lawn & Garden - Functional prototypes cut development time for Bosch

The Rapid Product Development capabilities of 3T RPD Ltd assisted Bosch Lawn and Garden Division in reducing the development cycle for the Bosch Rotak range to just 9 months, enabling it to be released at the GAFA trade show in September 2002.

Following the success of the Rotak 32 and 34 rotary lawn mowers released in Spring 2002, Suffolk-based manufacturer Bosch Lawn and Garden recognised a further opportunity to develop a larger 40cm cutter version.

In such a competitive seasonal market, late entry will result in significant loss of market share, sales and revenue. As well as avoiding these penalties, the early release of this electric rotary mower also meant that by May 2003 the Qualcast Powertrak 400 (variant of the Rotak 40) was reported by GFK magazine as being one of the best selling lawn mowers in the UK.

Applying lessons learnt whilst developing the 32cm and 34cm versions, Bosch asked 3T to produce nylon prototypes using their Selective Laser Sintering technology. Their ability to produce single piece parts up to 700 x 380 x 580mm on their EOS P700 Laser Sintering machines was crucial, as a complete lawn mower deck can be manufactured in a single piece in just 7 days, whereas they were previously made in 4 sections and bonded together.

By eliminating the need to fabricate the prototype deck, functionality, strength and delivery were all improved. The additional strength and functionality gave Bosch the confidence to assemble the prototype mower and to incorporate the production motor and cutter, then actually test its performance by cutting grass in a real life situation.

One of the key elements in the success of the previous Rotak models has been the Bosch PowerdriveT System motor. With a similar motor type to an electric drill, the motor spins at high speed and uses a belt drive to reduce the blade speed from 18,000 rpm to 3,500 rpm. The innovative reducing gear converts the high speed of the motor into enormous torque. This has resulted in a range of mowers that are not only very light, but display exceptionally high cutting power.

This significant weight reduction opened up the opportunity for the larger 40cm model. Traditionally, domestic consumers had been deterred from buying such a larger mower as they weigh an average of 26kg. This made them difficult to manoeuvre when mowing and also difficult to lift and store after use.

However, the Rotak 40 variants weigh in at just 12.5kg, making it possible to lift with one arm, hence making it more appealing to the domestic user. Despite its light weight, the PowerdriveT motor delivers an impressive 1700watts of power, the most powerful motor on the market at the time of product release.

Adrian Coussins, Engineering Project Manager at Bosch Lawn and Garden said, "The extensive use of functional prototypes during the design and development phase was critical in achieving our record 9 month new product introduction lead time. We were confident that any design issues had been resolved before committing to full production tooling."

Adrian continues, "As such, we achieved a reduced tooling lead time because no changes were required whilst the tools were being manufactured. Getting a prototype of a complete lawn mower deck in one piece in just 7 days from 3T means we are able to test and prove our designs much earlier in the development phase than was previously possible".

Paul Edwards, Sales & Marketing Manager of 3T says "We enjoy working with customers like Bosch Lawn and Garden as they have embraced the true functional capabilities of the Laser Sintering process. 3T have always promoted the value of functional prototypes, and here is a classic example of how they can significantly reduce new product development timescales."

There is now a Bosch Rotak mower to suit gardens of less than 700m². The Rotak 32 is ideal for smaller, compact lawns, the Rotak 34 for medium lawns, and the Rotak 40 for the larger lawn. Research indicates that the Rotak 40 is a popular choice with women who want a lightweight but robust mower.

It suits a wide variety of cutting conditions with 11 different cutting heights between 20mm and 70mm, which are all easily selected by a single centrally located lever. With a modern compact design, the mower features a large 50 litre rear collect grassbox to reduce time spent emptying. Practical and stylish rubber coated wheels ensure smooth running, and an integral rear roller provides the desirable striped finish.

The Rotak 40 is one product from a full range offered by Bosch Lawn and Garden in the UK.

For stockists call 01895 838782.

Home | Contact Us | Newsletter | Request A Quote | Case Studies | Latest News |About Us | Our Services | Seminars | Technical Data | Site Map

3T RPD LTD
Fulton Court, Wofford Way, New Greenham Park, Newbury, Berkshire, RG19 6HD, UK
Telephone: +44 (0)1635 580284 | Fax: +44 (0)1635 569857 | E-mail: post@3trpd.co.uk