Case Study: Sonic Communications achieves rapid in-house production of custom fit-for-purpose parts with Markforged

Sonic Communications - Customer Case Study

Sonic Communications, a Birmingham-based supplier of specialist audio and surveillance equipment to police, military and government customers, faced rising costs and long lead times from outsourced 3D printing and a machine shop-driven product cycle that could take up to a year. Seeking faster, more-customisable production and a way to work around supply‑chain shortages, Sonic explored Markforged technology (including the Onyx One, Onyx Pro and X3 printers and Onyx materials) to prove additive manufacturing’s value and win company-wide adoption.

In 2022 Sonic purchased eleven Markforged printers (five Onyx One, four Onyx Pro, two X3) and now runs them 24/7 to produce prototypes and end-use parts. Using Markforged has cut lead times from outsourced weeks to overnight for parts and shortened new product development from as much as one year to about three months, enabled lighter, ergonomic designs (for example the EHIU3 box and In Line Nexis button), reduced reliance on the machine shop, and let Sonic adapt housings to available electronics during chip shortages.

Sonic Communications

Sean Watson

Design Manager