Improved design for production and prepared for manufacturing, achieving target production costs
Client – Restangles – a consumer product company
Expertise Applied
- Product Design & Development
- Design For Manufacture
- User Interface Design
- Material Analysis
- Living-hinge engineering
- Rapid Iterative Development Cycles: Build-Test-Learn
- Prototype Development
- Manufacturing Handoff
Problem
Restangles had developed initial prototypes for a collapsible footrest that folds into a small form factor when not in use, but needed to redesign the product for production, and get manufacturing started at a reasonable per-unit cost.
Solution
SGW Designworks developed a unique single-part design that incorporates living hinges. This enabled low cost production using injection molded plastic.
Results / Outcomes
- Multiple prototype and testing cycles led to the optimal design and feature set
- The collapsible footrest successfully folds into a small form factor when not in use
- Tooling was built and production began in mid-2021, with per-unit costs in line with targets
Overview
Restangles identified a real problem to be solved. People of shorter stature (and with shorter legs) often experience posture issues or knee pain when their feet aren’t able to rest on the floor while seated. Restangles had developed initial prototypes for a collapsible footrest that folds into a small form factor when not in use, but needed to redesign the product for production — and get manufacturing started. They chose SGW Designworks as their product design firm because of our proven track record with consumer products, and our contract manufacturing capabilities.
Oftentimes, products that seem quite simple required a lot of design and engineering effort. Restangles was no exception. In order to keep production costs in check, a single-piece injection molded plastic design would be ideal. But to achieve this, multiple living hinges, snapping features, and stiffening elements would need to be designed into the product.
More specifically, product design and engineering efforts focused on:
- Living-hinge engineering
- Product stiffness
- Weight minimization
- Texture specification
- Design to minimize tooling cost
During development, we coordinated with our Malaysia production house to make sure the design would be 100 percent compatible with the production equipment.
| Hardware Developed | Technologies Leveraged |
|---|---|
| Living Hinges | Solidworks 3D CAD |
| Injection Molded Plastic | FDM 3D Printing |
| Solidworks Simulation FEA | |