Case Study: MAHLE accelerates high-voltage heater prototype validation with Protolabs

Mahle Protolabs Rapidly Machines 'Phase A' Validation Parts for Vacuum Casting

MAHLE GmbH, one of the world’s largest automotive suppliers, needed 40 highly complex aluminium parts for concept validation, assembly checks, and endurance and safety testing for a new generation of 800-volt high-voltage heaters. The company turned to Protolabs for CNC machining of prototype casing parts that needed to closely match the performance and properties of future vacuum-cast production parts.

Protolabs used its manufacturing analysis, expert DFM feedback, and rapid CNC machining to produce the parts in 6082 aluminium with minimal redesign needed. Protolabs delivered the first 10 parts in 6 days and the remaining 30 parts in 3 weeks, enabling MAHLE GmbH to validate the design quickly and proceed with testing on schedule, while benefiting from timely, efficient service.

MAHLE GmbH

Nicolas Edel

Pre-Development Engineer