iCONN CASE STUDY
Product Redesign for
Harsh Application Testing Device
iConn Systems developed a combination of overmold technologies to create synergy
and produce a rubust design for a fire detection manufacturer.
Fire detection system manufacturers rely on system checking equipment to troubleshoot and verify that the overall system is responsive and operational. We were approached by a customer that prototyped a testing device and was looking for a company to manufacture it. They were not completely happy with their prototype design as it was too large for a toolbox, let alone someone’s pocket. They wanted one handed operation, and the current design required two. The prototype tester was hard-wired, difficult to operate, and contributed to misinformation. This customer needed a company that could improve upon the design to make the device more accurate, compact, user friendly, and reduce cost as well.
Why it Works
This solution included the design and development of an extremely compact size product, approximately 75% smaller relative to conventional methods.
iCONN System’s Custom Overmold Tool
The design also allowed for additional features that were integrated into the shape of the overmold. Specifically, molded barriers that protect the rocker switch mechanism from impact damage and a recessed area to contain and protect the information label from field abuse and inadvertent removal. These are the types of synergies that iCONN looks for when designing overmolds for all applications.
The progressive overmolding techniques and engineered designs utilized within the development of the fire detection system resulted in a new product category for iCONN Systems that can benefit the entire industry. These engineering advancements created a benchmark for future designs in which electronics and electro-mechanical components like rocker switches can be integrated into harsh industrial applications successfully and reliablyusing iCONN’s overmolding technologies.
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