- ≈ 0%change in part cost versus the original design
- 1consumable PTFE insert – creating repeat sales
- 2design iterations, validated with 3D-printed prototypes
Overview
Develop a durable, cost-effective solution to prevent acid erosion on electrified steel components while maintaining compatibility with existing parts and ensuring long-term usability.
Problem
Acid corrosion
Electrified acid was corroding steel tracks over time, leading to frequent failures and costly replacements.
Compatibility constraints
The solution needed to align with the dimensions of already stocked parts to avoid expensive redesigns.
Sustainability
Frequent replacements of brush heads and components increased operational costs and created unnecessary waste.
Process
The project began with a focus on simplifying the design to reduce complexity and improve manufacturability. A PTFE (polytetrafluoroethylene) plastic insert was introduced to route acid flow and shield metal components from erosion, significantly enhancing durability.
Prototyping and testing were key to validating the solution. Initial 3D-printed prototypes confirmed the effectiveness of the PTFE insert in preventing erosion. However, early testing revealed that the original design constrained acid flow due to the small size of certain components.
A redesign introduced a consumable PTFE insert, making the product more robust while also creating a sustainable revenue stream through repeat sales of replacement inserts.
Explore in 3D
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Solution
The final design delivered key benefits:
Increased durability
The PTFE insert eliminated the need for frequent replacements caused by acid erosion.
Cost-effectiveness
The cost of the new part remained almost identical to the previous design, ensuring affordability.
Improved safety
The use of PTFE mitigated the risk of structural damage caused by acid erosion.
Sustainable revenue stream
The consumable insert design enabled repeat sales, benefiting long-term profitability.
This project successfully addressed a critical design flaw while introducing innovative materials and strategies, ensuring a more durable, cost-effective and scalable solution.