Challenge

Sonos needed a reliable partner to develop and prototype a revolutionary transducer system for the Arc Ultra speaker. The challenge was to enhance bass performance while shrinking the overall product size, requiring rapid iteration on complex, high-precision components.

Solution

Protolabs emerged as the ideal partner, providing rapid injection moulding and 3D printing prototyping services with Design for Manufacturability (DFM) analysis, enabling Sonos to refine designs quickly and test high-fidelity prototypes in real-world conditions.

Outcome

Delivered critical prototype components, including the innovative Sound Motion™ driver and spider assembly, allowing Sonos to achieve double the bass performance in a slimmer design while accelerating the development timeline.

Accelerated Prototyping with High-Fidelity Results

The challenge for Sonos was clear: incorporate a unique transducer suspension system and reduce the product's overall size while enhancing sound quality. Leveraging Protolabs’ expertise across 3D printing, CNC machining, and Injection Moulding, Sonos developed and tested numerous high-fidelity prototypes.

"Protolabs gave us early prototypes that we could configure and test in real-world conditions. This allowed us to move from idea to execution rapidly and confidently," said Lars Wouterse, Senior Hardware Development Engineer at Sonos. "Their speed and reliability helped us push the boundaries of what’s possible."

Protolabs’ DFM (Design for Manufacturability) analysis system enabled quick design iterations, aligning perfectly with Sonos’ experiment boldly ethos, of testing radical architectures and designs to push the boundaries of sound. Initial designs were 3D printed using Multi Jet Fusion (MJF) for flexibility. Protolabs held an interactive training discussion at Sonos’ facility to ensure their engineers got the full potential from the additive technologies available. As the project progressed, high-fidelity prototypes were produced via injection moulding. This iterative process allowed Sonos to refine the intricate design of the spider—a key component of the Sound Motion transducer.

Innovative Transducer Design: A Game-Changer

Traditional transducers use fabric material for the spider, but Sonos opted for a high-performance polymer, allowing for thinner, more compact designs. The result: a dedicated Sound Motion driver that replaces eight traditional woofers, delivering deeper bass without sacrificing clarity. Arc Ultra now features 14 transducers, compared to 11 in the previous Arc, including a more sophisticated three-way system with a dedicated Sound Motion™ woofer, midrange drivers and tweeters.

"The collaboration with Protolabs helped us achieve an immersive sound experience without compromising on design or space," said Naphur van Apeldoorn. "Their rapid prototyping capability ensured we could test assembly and performance early, an invaluable asset in such a complex project."

Seamless Global Coordination and Rapid Iteration

Protolabs played a crucial role in streamlining Sonos’ prototyping process. Protolabs account management and engineering team were instrumental in reducing lead times and coordinating across three continents to ensure that parts arrived on time for testing. This efficient coordination meant that every prototype was tested in real-time, keeping Sonos’ iterative cycles intact. The relationship between Sonos and Protolabs Consultative Design Service meant strong communication on urgent requests that were prioritised due to the critical lead time.

"Protolabs helped us move from prototype to production faster than we thought possible," added Naphur van Apeldoorn, Senior Manager of Hardware Development Engineering at Sonos. "Their commercial responsiveness and engineering expertise were vital to the success of Arc Ultra."

“Projects with such tight deadlines make the approval process even more important - Any lack of approval would lead to delays”, continues Naphur van Apeldoorn. “Before travelling internationally for the full approval process, Protolabs were flexible enough to host us at their Telford site to validate the parts before shipping, creating more certainty and confidence in the process.”

Pushing the Boundaries of Sound Engineering

The Arc Ultra project represents the most significant advancement in transducer technology in over a century. Sonos has set the stage for future iterations, driven by continuous innovation and rapid prototyping.

"Protolabs’ ability to deliver high-quality parts early in the process amplified Sonos’ commitment to fast iteration, allowing them to develop a truly revolutionary product," said Shay Mason, Account Manager, Protolabs. "Working closely with the Sonos team has been a true pleasure, and being part of an innovative project that personally interests me has been an additional bonus. I have thoroughly enjoyed being part of this partnership and seeing how well the Protolabs offering has aligned with their team and project requirements - And how at times, the Sonos team pushed our manufacturing capabilities beyond their limits and had successful results."

Conclusion

The Sonos Arc Ultra is a testament to the power of collaboration, innovation, and rapid prototyping. With Protolabs as a key partner, Sonos has set a new standard in home audio, proving that with the right support, even the boldest ideas can become reality.