Case Study: Triax Technologies accelerates speed to market with Protolabs' rapid overmolding

Triax accelerates speed to market with one manufacturing source for prototyping and production

Triax Technologies, a Connecticut safety and communications firm, set out to bring Spot‑R — an IoT wearable that detects slips and falls on construction sites — to market quickly while meeting tough requirements for waterproofing, serviceability and low‑volume production. As the company’s sole mechanical engineer evaluated assembly and sealing options, Triax turned to Protolabs for rapid prototyping and production services, including injection molding, rapid overmolding (ABS substrate with VersaFlex gasket), online design‑for‑manufacturability feedback and low‑cost aluminum tooling.

Protolabs implemented an overmolding solution and iterative manufacturability reviews that enabled Triax to switch from a glued housing to a screw‑accessible design with an integrated o‑ring gasket, producing an initial prototyping run of about 2,000 parts and completing roughly 15 design iterations with Protolabs’ applications engineers. The result: a waterproof, serviceable Spot‑R produced on demand, faster time to market with lower development cost, easier transitions from prototype to low‑volume pilots and production, and the agility to implement design changes without significant added tooling expense — all enabled by Protolabs.

Triax Technologies

Greg Probert

Project Engineer