i2Systems’ Newfound Use of Additive Manufacturing to Improve Quality, Eliminate Pain Points, and Increase Productivity In-House
In the ever-evolving landscape of manufacturing, technology remains a pivotal force driving innovation. At the forefront of this technological revolution is i2Systems, a company specializing in high-end architectural LED lighting. Cooper Henion, i2Systems’ Manufacturing Engineering Manager, provided an in-depth look into their journey, particularly in the adoption of 3D printing technology and the role Adia has played in this transformative endeavor.
Founded in 2003, i2Systems has built a wide portfolio of products, ranging from industrial parts in the marine elevator to grocery store and office lighting. Almost all of which, the company proudly designs and assembles in-house. i2Systems journey into the realm of additive manufacturing was sparked by a realization that some outsourced parts were falling short of quality standards. To address this issue, i2Systems partnered with Adia to bring this production in-house through the implementation of additive manufacturing technologies.
“Adia was very willing and supportive when it came to discovering the right opportunity.” Cooper Henion, i2Systems
The conversation with Adia began in October 2022 after inquiring about the Figure 4 Standalone. This inquiry prompted a thorough investigation into potential applications, revealing a significant pain point in their manufacturing workflow. A closer look at this component indicated that this issue could be efficiently addressed with the use of additive manufacturing. Once the application was confirmed, it was time to showcase the technology and confirm feasibility of Figure 4 technology. This was done by testing, printing and modifying geometries of the printed part.
Recognizing the potential of this new approach, Adia developed a comprehensive return on investment (ROI) analysis. This analysis was crucial in understanding the initial investment required to transition this process from a conceptual stage to full production. The results were promising, leading to the acquisition of three Figure 4 Modular machines. From there, all it took was a bit of support from Adia to get the team at i2Systems up and running.
“Anytime we have a question, they just say, “I’ll come out tomorrow”, and they come right out. In terms of getting the machine set up, I didn’t really have to do much besides tell them where it was going.” Cooper Henion, i2Systems
Adia’s first task was the installation and configuration of the three Figure 4 Modular machines. Once in place, i2Systems joined Adia for several training sessions, which encompassed operator training and instruction on design for additive manufacturing (DfAM). These sessions were crucial to ensure the team was well-equipped and ready to efficiently operate the new machinery, ultimately enabling them to achieve their goals effectively.
Success came quickly for i2Systems which led to the acquisition of three more machines to scale demand, just months after their initial investment. Today, i2Systems’ additive team is comprised of six individuals who work together to effectively design, prep, and print high quality, consumer ready parts.
Henion’s advice to newcomers? “Do your own homework and explore, but also engage the experts and support from a company like Adia to accelerate your growth.” Cooper Henion, i2Systems
Looking back on i2Systems’ journey over the past year, Henion has noticed significant advancements not just in product quality but also in reduced production costs and lead times. While they are officially up and running, Adia remains an integral part of their operations. Adia has become an extension of i2Systems’ team and has continued to provide unbounded support, training, and materials as needed. As an integration partner, Adia has accelerated their adoption from initial installation to full production in 6 months.
Reflecting on their work with i2Systems, Greg Gondek, President of Adia, admires the strong alignment among i2Systems’ leadership, culture, and their joint commitment to innovation. Gondek praised Mark Zampini, President of i2Systems, and the entire team for their remarkable achievement — navigating a new technology from exploration to production in an astonishing six months, a rarity in the industry.
“We have a long list of clients we have helped over the past thirteen plus years, and It’s always exciting to work with one where the top management, the culture and enthusiasm for innovation are all lined up in such a positive way. Mark Zampini, the president has fostered a great organization that accomplished what very few have, in bringing a new technology from investigation to production in record time of six months! He and the entire team need to be commended for this accomplishment!” Greg Gondek, President at Adia
i2Systems and Adia exemplify the transformative power of technology and strategic partnerships. Their success story showcases how innovation and collaboration can lead to remarkable growth. Their journey highlights not just technological advancement, but also the synergy between expertise and support. Combining dedication and collaboration, they’ve pioneered advancements in production, quality, and efficiency. Together, they stand as an inspiring model for accelerated growth and continue to demonstrate the extraordinary outcomes that emerge from a combination of vision, dedication, and collaboration.