determined during the development stage.
With our experience in product development we understand how important it is to consider all those factors in the engineering phase. Our in-house experts for tooling & manufacturing already ensure the producibility of each component at an early stage of the engineering process. This allows us to minimize development time and production cost and enables a smooth transfer to the production phase.
Setting goals is everything. Therefore we establish for all projects a detailed specification list. Brainstorming gives the variety of possible solutions, which will be rated and verified in the concept engineering phase. In most cases material selections, calculations and simulations are part of the engineering phase to ensure compliance with the product requirements.
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Cost reduction and material studies combined with load simulations.
Re - engineering of an existing high end bathroom scale with the goal to reduce cost and lowering the scrap rate in mass production. The main constraint was to keep the look true to the previous model.
By simplifying the structure and manufacturing process we were able to lower the manufacturing cost by 40% while maintaining appearance and functionality. With the complete documentation of 2D&3D files and bill of material ready for manufacturing, the adjustment in the production for the new model was smooth and without problems.
Multidirectional buttons with firm and accurate touch feeling
Engineering of a front panel for a gas analyzer device. Multiple parts should be assembled in a simple and intuitive way to keep manufacturing costs at a minimum.
Thinking about the assembly process in the engineering stage is crucial for the production later on. The complete data set with 2D&3D files ready for manufacturing also include the bill of material and clear assembly instructions.
Engineering of high end camera equipment with challenging design and multiple functions.
Integration of all mechanical and electronic functions while maintaining the design concept. Furthermore the device must be drop proof and withstand the load of a large flash.
Based on the design file, we built up the 3D file with all relevant features for tooling and assembling. After the prototype phase to confirm all functions, the final 2D&3D drawings with all necessary manufacturing information and a bill of material were established.
Plastic housing with integrated living hinges
Engineering of a cartridge housing for razor blades according to customers design file and specification list. Low cost, easy to assemble, suitable for high volume mass production
Defining the right materials is a key factor for a successful product. With the combination of PP material, living hinges and snap hooks, the housing can be constructed as a single part. After the injection molding only a simple folding process is needed to form the final housing. The complete 2D&3D data ready for production, allowed a quick progress to the tooling phase.
IP68 and intrinsically proof engineering for industrial device
Integration of all mechanical and electronic functions while following the design file. Next to the requirements IP68 and drop proof, an additional challenge was to make the product intrinsically safe to operate safely in hazardous environment with flammable gases.
Working together with the customer to fulfill all regulations & norms is an important part during the engineering stage. After that a complete set of data with 2D &3D files and a bill of material ready for manufacturing were provided.
Simulation to determine stresses and deformation
Locate and eliminate areas of stress concentrations under maximum motor load. We have also analyzed displacements of gear components to ensure 100% functionality and efficiency under load in regard to the allowable gear tolerances.
Full FEA report with assumptions of different load cases, constraints, meshing and results. We also include proposals for improvements and show the comparisons thereof.
100% reliability is a must for medical devices.
Engineering of a clamping device for a medical mixing system. The device must clamp bottles with a range of 15 – 35mm with a constant and accurate force. High precision and reliability of the clamping mechanism in a clean room environment, combined with high life time expectation made this project challenging.
Brainstorming, motion analysis and force calculations were necessary to define a suitable drive system for the gripper. After modeling in 3D, working prototypes successfully passed the testing phase. Final documentation included all files ready for manufacturing with 3D&2D files and a bill of material.