Modeling
When implementing the 3D model, we strictly adhered to the manufacturer’s specifications, which called for a sophisticated interlinking of design and engineering data within the PTC CREO software package.
Integrating the existing handle and switch components and the various battery systems proved to be a particular challenge.
Thanks to parametric surface modelling and a robust construction system, the necessary elements were seamlessly integrated into the design.
DFM
The hedge trimmer's housing is based on a clam-shell design surrounding the technical components. Following this principle, all design and functional elements must be oriented and drafted in the direction of demoulding.
Using the draft and undercut analysis functionality, we worked to ensure the part could be demolded and avoided undercuts. Where necessary, we proposed appropriate adjustments.
To ensure the most effective integration possible of the technical component layout, which was developed in parallel with the design detailing, and to guarantee compliance with the required tolerances, the design and engineering data sets were continuously cross-checked.
This workflow requires a high degree of precision in model development and meticulous file management. We were able to ensure this through rigorous quality control.
b-surfacing and overmould creation
In addition to the outer A-surface of the housing components, we also provided a B-surface set that defines the material thickness. A third, intermediate surface set was used by the engineering team to connect stiffening ribs and structural elements.
The design language of the product family is characterised by a black overmolded component. In the grip area, a rubberised material with a textured surface is used to ensure optimal grip. Based on the design sketches, we created the volumes of the overmolded components required for the 2K injection mould and integrated them into the housing shells, ensuring consistent material thicknesses and the necessary sealing joints.
