![[Translate to English:] Biocase: Kleinserie aus Originalwerkstoff](/fileadmin/_processed_/8/e/csm_201809_Biocase_7047f2d6db.jpg "[Translate to English:] Biocase: Kleinserie aus Originalwerkstoff")
With the emotionally charged product, he wants to create awareness that a lot of crude oil is used for conventional plastics. A father's advice led him to 1zu1, which enabled rapid product development with aluminum tools and inexpensive production of the covers using injection molding.
"Founder" is on Dominic Zajonc's business card. In fact, his startup “Biocase” is still in the process of being established. He developed his idea of a mobile phone cover made of bio-plastic, produced regionally, until it was ready for the market. Negotiations with major sales partners are now pending.
A German citizen who now lives in the Swiss canton of Obwalden, Dominic Zajonc studied mechanical engineering at Lucerne University of Applied Sciences and Arts. Sustainability has always been an issue for him: „At some point I realized how few people know that two and a half kilos of crude oil are needed to produce one kilo of plastic. This gave rise to the idea of using a product to create awareness about the consumption of resources.“
Dominic Zajonc inspired three fellow students to join his project – one of whom is now responsible for the design, another for commercial matters and the third for marketing. The first design drawing for the required mechanical engineering was quickly produced, however, the first quotes he received from manufacturers were out of reach from a financial perspective. But then 1zu1 came into play.
In an interview with Christian Vonach, head of internal sales at 1zu1, and Dario Loss, project manager in the Tooling division, Zajonc describes the origins and development of the project.
Mr. Zajonc, where did you first hear about 1zu1?
Dominic Zajonc: We were looking for an implementation partner for our Biocase project. We had the design drawing, we had an idea of the product – but we didn't yet have a prototype with which to approach potential distributors. In order to be credible when it came to the topic of sustainability, we wanted the production to be based within our region. That's why we were looking for a local partner.
I come from a family with a great affinity for injection molding. My father specifically advised me to talk to 1zu1.
Why a cell phone case of all things? Surely that's a very crowded market?
Zajonc: We're not only interested in developing a product and being commercially successful with it. Our main goal is to raise awareness. The cell phone is a status symbol for many people; they choose their case carefully. In this way, we can ensure that they also consider the material, including from an ecological perspective.
In addition, we need a product with an attractive margin – bioplastics are significantly more expensive, as is local production compared to mass-producing a million units in China.
How was the project then implemented?
Zajonc: We first contacted 1zu1 in 2016. Production of injection-molded parts with aluminum tools was appealing to us for several reasons. On the one hand, this means that small changes can be made very easily during product development. On the other, the costs of conventional injection molding with steel molds are at least two to three times as high.
Christian Vonach: We've always worked exclusively with aluminum tools and can therefore offer attractive solutions for the customer, especially for product development and small series. Depending on the component, we can produce up to 50,000 or more pieces from a single mold.
Dario Loss: In this case, the product seemed relatively simple; a cell phone case of this kind doesn't have a particularly complex architecture. Nevertheless, every product has its challenges during development. In this project, it was important to find the right elasticity with the specified plastic. It had to be possible to pull the case over the smartphone without much force and ensure its sits firmly in place. In addition, the design-related requirements were strict: perfect surfaces, no burrs, special colors.
How did you choose the type of bioplastic?
Zajonc: We had originally chosen a corn and sugar-based bioplastic. In order to finance the development and raise awareness of the project, we then set up a crowdfunding campaign, which was also widely reported in the media in Central Switzerland. Nevertheless, we didn't achieve the desired reach and failed to raise the amount of money we had hoped for.
We received important feedback about the project, in particular concerning our use of maize, i.e. a foodstuff, in the production process. So we switched to castor oil as the raw material. Our case is now actually 97 percent „organic“. The remaining three percent are the additives needed for polymerization. These are necessary for the linking of the molecules, which gives the material the necessary properties.
Was 1zu1 involved in the selection of the material?
Vonach: The choice of material is always up to the customer. If required, we only establish contact with the supplier. Otherwise the material used by Customer A for their products would end up with Customer B via our recommendation – and possibly even with a competitor. That's why, in principle, we don't interfere.
When the crowdfunding failed to reach the desired goal, what happened next?
Zajonc: We had actually almost given up on the project. Following our appearance in the media during the crowdfunding phase, we received enquiries from well-known companies asking what the product would look like. This motivated us to make a second attempt.
In the meantime, new smartphone models had been launched. This led to an adjustment of our goal – ONE case that fits several models. There are deviations of 0.3 millimeters in length and width as well as slightly deviating positions of the camera lens. This increases the requirements regarding accuracy and elasticity of the plastic parts during production.
Loss: In production, the bioplastic behaves almost like a conventional injection-molding material. The different additives and colors pose a particular challenge. You need to gather experience with every type of plastic, for example with regard to elasticity or material shrinkage in the mold when it cools down. The cover must not be too tight or too loose.
Even with color additives, it takes a few trials to achieve the exact desired result. The wishes of the designers were quite specific – we had to prevent any color deviations. Normally, the function of the part is the main focus with prototypes. In this case – for the series part – the product's haptics and appearance are just as important.
You are using an aluminum tool. What are the advantages and disadvantages of this?
Loss: Since we're dealing with very manageable quantities, there are actually only advantages. Due to the modular design and the properties of aluminum, changes can be made without having to remake the entire tool. We can machine the aluminum inserts with our milling machines and often deliver new parts in just a few days. In the product development phase, the time savings are enormous – and the costs are a fraction of those for steel tools. The thermal conductivity coefficient is also better than with a steel tool.
Zajonc: In fact, the quantities of up to 15,000 shots per tool are sufficient for our concept. These advantages made the project affordable in the first place and enable us to remain flexible.
Are there customs issues with deliveries from Austria to Switzerland?
Vonach: No, in relation to the customer we are effectively a Swiss company with our own tax ID in Switzerland, which means we can also declare Swiss VAT. The customs clearance is taken care of by 1zu1. In specific cases we have produced on a Monday and on Tuesday the customer received their package.
What are the next steps for the Biocase?
Zajonc: In February 2018 we received a small order from the Gurtenfestival, a well-known Swiss rock festival. We delivered several hundred branded cases, which were sold at the special price of 30 Swiss francs.
Loss: As far as branding is concerned, we're still testing to see whether digital or pad printing delivers the most durable results. Our in-house facilities include a wide range of printing technologies.
Zajonc (takes his smartphone out of his pocket): We also subjected all our cases to an endurance test. The small order from the Gurtenfestival has enabled us to gain some experience and gives us a point of reference in our ongoing discussions with the major network operators and mobile phone manufacturers.
Interviewed: Dominic Zajonc is the founder of the Swiss startup Biocase. Christian Vonach is head of internal sales, Dario Loss is a project manager in the Tooling division at 1zu1 in Dornbirn. The interview was conducted by Wolfgang Pendl Werner Sommer; photos by Miro Kuzmanovic and Darko Todorovic.
