UK product design consultancy case study | Manufacturing housing system for industry
ESCCO printed on gantry system housing in factory
ESCCO logo graphic

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.

A design that cuts manufacturing costs

Following an analysis of potential alternative materials, we redesigned 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 continued to serve its function. We analysed the existing model to replicate key features. Then using our engineering expertise, we produced a design that both worked as expected and drastically reduced the housing cost.

We succeeded in transforming a four-component assembly into a single item. It utilised geometry profile to build the required structural integrity into the new design. As the new gantry housing system 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. This means that old components could be gradually phased out – even on existing stock.

CAD imagery showing the redesign of the ESCCO gantry system before the manufacturing stage

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