Prototype Development Cost Overruns
Definition
Prototype development for fuel cell components like flow field plates involves frequent engineering changes, where rapid prototyping (FDM) takes 1 hour vs CNC at 2 hours and MEMS at 12-36 hours, causing overruns in time-sensitive iterations.
Key Findings
- Financial Impact: AUD 500-2,000 per prototype (10-30 hours at AUD 100/hr labour + materials)
- Frequency: Per engineering change order in R&D cycles
- Root Cause: Lack of standardized DFM for change orders, leading to process trial-and-error
Why This Matters
The Pitch: Fuel cell manufacturers in Australia 🇦🇺 waste 10-30 hours per prototype on inefficient change orders. Automation of process selection and AM simulation eliminates this overrun.
Affected Stakeholders
Process Engineers, Prototype Technicians, R&D Managers
Deep Analysis (Premium)
Financial Impact
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Current Workarounds
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Methodology & Sources
Data collected via OSINT from regulatory filings, industry audits, and verified case studies.
Related Business Risks
Rework from Poor Manufacturability
Capacity Loss from Manual Prototyping
Cleanroom Energy Overrun
Contamination Batch Rejections
TGA GMP Clearance Delays
Cleanroom Qualification Downtime
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