How Dynacast Delivered Precision for SICK’s LiDAR Sensor

When miniaturization meets industrial-grade durability, the stakes are high. For SICK, a global leader in sensor technology, designing the picoScan100 2D LiDAR sensor meant pushing the limits of engineering—requiring a manufacturing partner to deliver precision, complexity, and reliability in one of the smallest, most sensitive components on the market.

The Challenge: Tiny Sensor, Big Demands

SICK's picoScan100 posed a unique engineering dilemma. The sensor housing had to be incredibly small, mechanically intricate, and tolerant to the rigors of industrial environments—all while ensuring exact internal tolerances for stable lens placement. Complicating matters further were minimal draft angles and the necessity for flawless shot accuracy, making traditional manufacturing approaches difficult and error prone.

The Solution: Precision Engineering from Concept to Completion

Recognizing the sensor’s complexity, SICK turned to Dynacast for a solution that would combine engineering expertise, process control, and collaborative innovation.

1. Collaborative Design Support

Dynacast was brought in early to help optimize the housing’s geometry, ensuring manufacturability without compromising function. This proactive partnership allowed design and production to align from day one.

2. Simulation-Driven Precision

By leveraging simulation software alongside deep die casting expertise, Dynacast fine-tuned the tooling and process flow—mitigating risks before production began.

3. Precision Microcasting

With a focus on gating and overflow design, Dynacast achieved flawless mold filling—ensuring dimensional integrity and consistent part quality at micro scales.

The Results: Flawless Execution, Satisfied Partners

SICK’s expectations were not only met—they were exceeded.

• Seamless Integration: The sensor housing was implemented smoothly, without the need for post-production corrections.
• Perfect Performance: Every unit met the stringent performance requirements essential to the LiDAR system’s functionality.
• Customer Satisfaction: SICK lauded the collaboration and outcome, with Dynacast recognized for a well-executed strategy that delivered value from start to finish.

“[Dynacast delivered] smooth implementation of the entire project without additional corrections.” – SICK

“SICK was a very satisfied customer thanks to our implementation strategy.”
– Markus Verini, Business Development Manager, Dynacast Europe