Problem

Acid Corrosion: Electrified acid was corroding steel tracks over time, leading to frequent failures and costly replacements.
Compatibility Constraints: The solution needed to align with the dimensions of already stocked parts to avoid expensive redesigns.
Sustainability: Frequent replacements of brush heads and components increased operational costs and created unnecessary waste.

Process

The project began with a focus on simplifying the design to reduce complexity and improve manufacturability. A PTFE (Polytetrafluoroethylene) plastic insert was introduced to route acid flow and shield metal components from erosion, significantly enhancing durability.
Prototyping and testing were key to validating the solution. Initial 3D-printed prototypes confirmed the effectiveness of the PTFE insert in preventing erosion. However, early testing revealed that the original design constrained acid flow due to the small size of certain components.
A redesign introduced a consumable PTFE insert, making the product more robust while also creating a sustainable revenue stream through repeat sales of replacement inserts.

Solution

The final design delivered key benefits:
Increased Durability – The PTFE insert eliminated the need for frequent replacements caused by acid erosion.
Cost-Effectiveness – The cost of the new part remained almost identical to the previous design, ensuring affordability.
Improved Safety – The use of PTFE mitigated the risk of structural damage caused by acid erosion.
Sustainable Revenue Stream – The consumable insert design enabled repeat sales, benefiting long-term profitability.
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This project successfully addressed a critical design flaw while introducing innovative materials and strategies, ensuring a more durable, cost-effective, and scalable solution.

Our Role/Responsibilities

Lead Designer & Engineer | Concept Development | Prototyping | Optimisation