Case Study: Hypsole brings cleat guards to production faster with Carbon DLS

Hypsole’s Cleat Guard Dream Gets to Production Faster with Carbon

Hypsole, a company creating protective cleat guards for athletes, faced significant challenges bringing their product to market using traditional injection molding. The complex design of the guards led to warping and quality issues, and the high cost and long lead times for creating custom molds made iterative design and prototyping prohibitively expensive and slow. They turned to vendor Carbon and its Digital Light Synthesis™ (DLS™) technology to find a better production solution.

By utilizing Carbon's additive manufacturing platform, Hypsole was able to rapidly iterate on their design with Carbon's team, avoiding the need for expensive tooling. The Carbon DLS process provided consistent, high-quality parts with the durable EPU 46 material, which was used for both prototyping and final production. This approach cut the development and production time down to 12 months, a significant reduction from the estimated 18 months required for injection molding, and enabled Hypsole to successfully launch a functional and aesthetically pleasing product.

Hypsole

Jes Christian

Founder