Project · Product development + Patent drawings
Optimized Chafer
A reverse-engineered redesign of a successful wire chafer — fewer parts, lower cost, better nesting for shipping.
About
The client needed a redesign of their successful Wire Chafer. We were able to make the design more efficient to produce — with fewer parts and lower cost — and also improved its nesting ability to allow for cheaper shipping and storage.
A factory fire had destroyed the old plans, so the redesign had to be done by reverse-engineering an existing model. We created new detailed 3D and 2D CAD for the necessary factory bending operations, plus animations of the 3D models for advertising purposes. The revamped manufacturing process was a huge success.
Challenges
Recreating CAD documentation after the original tooling was lost in the factory fire. Redesigning the wire model to decrease part count and manufacturing costs. Developing detailed CAD specifications for bending operations.
