The aim for this project was to find creative ways to streamline manufacture by reducing component expenditure. When manufacturing a large piece of industrial machinery with hundreds of components, even slight cost savings can make a big impact. We worked with our client, Escco, to find a low-cost alternative for their gantry system housing which was made from laser cut and folded components that were welded and powder coated. Our engineering and design team saw a huge opportunity to reduce costs.

Designed to cut costs


Following an analysis of potential alternative materials, we re-designed the gantry housing system so it could be vacuum moulded from 6mm thick ABS plastic. This presented several manufacturing and performance challenges so that it continues to serve its function. We analysed the existing model to replicate key features and using our engineering expertise, we produced a design that both worked as expected and drastically reduced the housing cost. We transformed a four-component assembly into a single item utilising geometry profile to build the required structural integrity into the new design. As the new housing included a single manufacturing process the lead time was also reduced so our client benefited further from their just-in-time system. We added attractive styling elements and also ensured that the new design could be retrofitted so that old components could be gradually phased out – even on existing stock.