The Opportunity:

We have provided this customer’s flagship dynamics cart for years. They presented us with a new challenge; our customer wanted the same functionality as the present cart, to retain the existing form factor, and to maintain functionality with existing add-ons. Then, integrate a whole suite of new sensors, probes, and detectors into the cart itself, all the while keeping the price point substantially lower than that of a competitor’s offering.

Solution

Far and away the most important part of the cart was an optical encoder capable of reading its position real-time down to an accuracy of five thousandths of an inch. Our greatest challenge was to ensure that the encoder would read consistently and be immune to any imperfections in the surface it rolled on. A design solution was created to isolate the optical encoder from the rest of the assembly, ensuring that the encoder would always be providing accurate data. Since we were working off an existing design, we improved and cost-reduced several carry-over features from the previous rendition of the cart.

Process and Product Details

  • Product Redesign
  • Plastic Injection Molding
  • TPR Overmolding
  • Machined Plastic Parts
  • Decals and Labels
  • Pad Printing
  • Product Testing and Validation
  • Assembled in the US
  • Product Modularity
  • Product Integration
  • International and Domestic
  • Sourcing

Complexity Level

Intense