There is a recurring pattern in many development projects: the initial solution approach is often technically possible, but unnecessarily complex, expensive or difficult to produce in practical use. This was exactly the case with the project we would like to report on.
Problem: Functionality given, production effort expandable
Our customer approached us with a request to manufacture an aluminum clamping system with complex kinematics. The goal was clear – to fix components securely and precisely. However, even during the initial analysis, it became clear that although the solution met the functional requirements, it was far from optimal in terms of manufacturing effort, material usage and costs.
Re-engineering with a focus on the essentials
Instead of simply implementing the original concept, we took a step back and looked at the actual function of the system.
- What movement is needed?
- Where does complexity arise that does not deliver added value?
- How can the assembly process be simplified?
This re-engineering quickly resulted in a completely new approach: a modular plastic solution that works completely without kinematics and instead relies on a plug-and-play principle.
The components shown in the pictures are the result of this process. Form follows function – and not the other way around.
Plug-and-play instead of complex mechanics
The newly developed solution can be connected, neatly snapped into place and released again without tools. The result:
- Significantly lower construction costs
- No moving parts that can wear out
- An intuitive operating concept
- High repeat accuracy in use
- Additive efficiently producible in series
Additive manufacturing in particular was a decisive factor here: it not only enabled fast prototype runs, but also direct implementation in cost-effective series production.
200 % cost reduction – with improved functionality
Perhaps the most impressive effect of this project was that we were able to reduce the production costs for the components by around 200%.
Instead of milled or assembled aluminum components, the result is a durable, robust plastic system that requires significantly less material and processing. This saving not only has a positive effect on our customer’s budget, but also on:
- the sustainability of the product
- the delivery times
- Scalability with increasing quantities
From the idea to series production
The final components can be stacked to save space, packaged efficiently and produced in large quantities. The transition from prototype to series product went smoothly and without additional investment in expensive tools.
Conclusion: Re-engineering pays off
This project impressively demonstrates how much potential there is in consistently questioning existing solutions. By reducing complexity and focusing on functionality, sustainability and efficiency, we were able to transform an originally sophisticated aluminum clamping system into a smart, cost-efficient and user-friendly plastic solution.
Your project in the best hands
At IBK Engineering, we combine technical expertise with state-of-the-art production technology. We offer our customers the best of both worlds: Innovation and reliability.
Do you have a project that we can support you with? Contact us, we will be happy to advise you!