KST Moschkau: Using FX20 for Low-Volume Production

When the demand for a new product exceeded expectations, KST Moschkau, a security systems manufacturer, utilized the FX20 to streamline production and avoid messy supply chains. The results were impressive, as the FX20 reduced lead times from 3-4 weeks to just 2 days. Additionally, production costs were reduced by 1/6 compared to using several aluminum components from third-party CNC shops.

The Customer

KST Moschkau GmbH is a family-owned business that was established in 1985. The company operates as a project system house, specializing in the development of intricate system solutions in the main areas of Broadcast & ProAV, media technology, and AV security systems.

KST Moschkau has a system construction division that produces an extensive range of components, products, and systems using up-to-date production technologies. Recently, the company has expanded its product portfolio to offer out-of-the-box solutions that cater to specific customer needs.

The Challenge

In February 2020, KST commenced the production of the KST-OH series, which is an outdoor housing designed for the Panasonic PTZ camera. However, the demand for their product exceeded their expectations, and they soon realized that their current manufacturing process was not scalable for small series production. Initially, the camera housing was designed in-house, and the components were outsourced to CNC shops for machining.

As the housing contained several aluminum plates, customizing low-quantity orders became expensive, and the iterations became time-consuming. The process became labor-intensive, requiring many steps to obtain and assemble the numerous components for a single product. Additionally, their dependence on third parties left them with no control over shipment delays, forcing them to postpone projects further for their customers.

The Solution

The KST team decided to take control of their supply chain by printing the majority of their product on their own Markforged FX20 machine. This allowed them to print three components on a single print bed, measuring 525x400x400 mm, rather than outsourcing to machine shops. By using the FX20, they saved costs and accelerated production while maintaining the highest quality standards for their products.

Printing housings on the FX20 allowed them to prototype and iterate on designs before delivering them to customers. The Onyx material used in the printing process provided an excellent surface finish and toughness, making the housing resilient to harsh outdoor weather conditions such as rain, UV rays, and extreme temperature variations. After post-processing, the housing was not visibly different from its aluminum counterpart, except for being slightly lighter. This new method of manufacturing ensured the housing could withstand various weather conditions while maintaining its quality and durability.

“By switching to Additive, this immediately lowered costs and accelerated production immensely - giving us the flexibility to prototype and iterate on designs on our own terms before validation. The excellent surface finish and the toughness of Onyx helped us maintain the highest quality standards we set for our products.”

– Felix Moschkau, KST Moschkau

The FX20

The FX20 brings the Digital Forge and Continuous Fiber Reinforcement to a new realm of parts, problems, and industries.

• Massive builds, faster
  The FX20 pairs size and throughput to make larger builds at incredible speeds, delivering the transformational benefits of The Digital Forge at a new scale.
• Flight-ready functional parts
  Built for everything from performance tooling and fixtures to flight-ready production parts, this large format 3D printer can reinforce ULTEM™ 9085 Filament with continuous carbon fiber.
• Production-ready performance
  A precision-designed, sensor-driven production 3D printer delivers breakthrough reliability and performance with a simple user experience.