Case Study: Alea Labs achieves 4-week injection-molded T1 samples and faster time-to-market with Fictiv

How Alea Labs partnered with Fictiv to prototype and manufacture injection molded parts for their smart HVAC system

Alea Labs, a consumer electronics startup developing a smart HVAC system, needed to prototype and manufacture several complex plastic grilles and vents (seven sizes) that required careful design for airflow and a special high‑glass-content molding compound. They were looking for a local manufacturing partner that could deliver fast lead times and hands‑on design‑for‑manufacturability feedback — needs they brought to Fictiv for injection molding and tooling support.

Fictiv provided DFM guidance, refined the grille designs for tooling and mold flow, managed the manufacturing process (with local technical support and an attentive account manager), and coordinated production with its partners to accelerate delivery. As a result, Fictiv produced injection‑molded T1 samples in four weeks—shortening what is typically months‑long lead time to weeks—enabling rapid iteration, predictable costs, and a committed supplier relationship for future sizes and redesigns.

Alea

Hamid Farzaneh

CEO and Co-Founder