WHEN THE PRODUCT MUST BE STRONG BUT LIGHTWEIGHT The client engaged SGW Designworks with a bold vision for improved drive systems in a specific industrial application. Low production cost and light weight were critical to the commercial success of the concept, as was the ability to support massive loads. For various reasons, injection molded plastic needed to be the primary material used ion this large, robust assembly. While the client company had a clear vision for the product itself, they lacked the internal capacity for complete product design, engineering analysis, and production of a complete design package ready for production. It was clear than hiring a qualified product design firm was the best path to success. PRODUCT ENGINEERING PUSHING THE LIMITS OF MOLDED PLASTICS The loads that the drive system must support push the entire drive assembly to the limit. Advanced finite element analysis, simulation, and geometry iteration were required to define designs that will provide reliable service in a critical application. This drive assembly was analyzed and engineered by SGW Designworks to be manufactured entirely from injection molded glass-filled nylon. DuPont joined the project team to help with the specific custom formulation. The final design was comprised entirely of injeciton molded plastic, with the exception of the hub. PRODUCT DESIGN FIRM AS A STRATEGIC PARTNER By engaging SGW Designworks, the client (an emerging business) was able to develop and launch a cutting-edge new product. department. This relationship allows the client business to have the product engineering capabilities of a large company, without the overhead of a full internal Research & Development department.