Sonic Communications cuts product development time by 75 % with Mark3D UK and Markforged

Sonic Communications, based in Birmingham, UK, develops specialized audio and surveillance equipment manufactured directly to technical specifications. Founded in 1977, the company employs over 100 people and serves hundreds of clients, including the UK Ministry of Defence, the Royal Navy, and police forces worldwide. Through the reliable provision of technical equipment and adaptation to customer requirements, Sonic has established itself as a competent and trusted supplier in its field.

Sonic Communications (Int) Ltd is a market-leading, global provider of specialized equipment, solutions, and services for law enforcement, military, government agencies, and industry, with over 40 years of experience. A key part of Sonic Communication's success is its attention to detail and its focus on customer needs.

Sonic's training programs are tailored to each customer's requirements, and the same applies to its products. With the purchase of 11 Markforged 3D printers, installed and supported by Mark3D UK Limited, Sonic Communications has been able to impress its customers with rapidly produced prototypes. “The curves and texture make handling easier and more ergonomic. Customers love them,” says McDonald. “As soon as they see and feel a 3D-printed part, they want another one.”

Many of Sonic's employees have been with the company for over 30 years. While they were open to new ideas, they needed to see the practical benefits of 3D printing before more employees would adopt the technology.

To convince them, Sean and Kevin partnered with Darren, a new manager in the vehicle shop. Darren, who spends a lot of time in the machine shop, was looking for ways to speed up certain processes. Together, using Markforged printers, they developed products that the team could immediately use in specialized police and military vehicles.

Darren now uses Markforged as the standard technology for product development, increasing his team's productivity by reducing his reliance on the machine shop. He can now modify a box so that the holes are exactly where he needs them, instead of having to start from scratch with CNC machining each time. And, most importantly, he's empowering his team to do the same—saving time and increasing productivity.

In just six months, Markforged has already helped Sonic develop products such as the EHIU3 application box and In Line Nexis's new push-to-talk button, which connects a single or dual two-way radio to a headset. The company can now go from design to finished product in a quarter of the time it would have taken to manufacture the same product in its own workshop.

Thanks to the speed and agility of 3D printing, Sonic can now develop new product families—small variations of existing products that allow customers to perfectly tailor their products to their needs.

To handle the increasing number of customer orders and ensure they can be fulfilled immediately, Sonic operates its fleet of Mark3D UK-installed Markforged printers around the clock.