Case Studies

     
Electronic Headset Linear Bearings Marker System for Promotional Advertising Medical Products

Case Study: Electronic Headset

Aztec Tool consulted in the design and electronic packaging for this state-of-the-art voice recognition microphone with noise cancellation properties.

Customer Requirements

  • Design an aesthetically pleasing housing.
  • Have an overall design that is ergonomic and cost effective.
  • Must have prototype pieces molded in 8 weeks.

Aztec's Solutions

The customer supplied design drawings developed by individuals with little plastics experience. We took the concept drawings and developed a product that met the criteria the customer required. The customer was concurrently engineering this product during our eight week design and prototype fabrication cycle.

Milestones

  • Created CAD documentation that was reviewed for engineering purposes and by the customer.
  • Created STL files to manufacture SLA models for proof of design.
  • Designed and manufactured prototype tooling for 11 parts in eight weeks.
  • Ran prototype tooling to manufacture 100,000 assemblies.
  • Helped the customer get the product line ready for production in the overseas market.

Results

Aztec exceeded all of the project milestones outlined by the customer. This was achieved despite concurrent engineering efforts during the eight week design to prototype cycle.

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Case Study: Linear Bearings

Aztec Tool was commissioned to consult and develop a new product line that was cost effective and provided benefits to the end users.

Customer Requirements

  • Needed to have their current tooling simplified.
  • Needed a new design created that would reduce the tight tolerances necessary to mold the existing product.
  • Wanted the new design to also allow for efficient manual assembly with future automation expected.
  • Wanted prototype and production tooling developed.

Aztec’s Solution

The design the customer was using at the time was a complicated two-piece cylindrical design. We developed a preliminary retainer from previous product designs. Prototype injection mold tooling was completed and parts were available in two weeks for customer evaluation. The customer recognized the benefits and committed to full product prototype tooling.

Project Milestones

  • Created simplified 3-D product design for customer evaluation.
  • Provided SLA and FDM prototypes.
  • Designed and manufactured prototype tooling for each component in two weeks.
  • Molded prototype components in various resins for customer testing.
  • Assisted customer in developing a variety of sizes and styles for the product that could permit the use of interchangeable tooling components.
  • Designed and built production and tooling for 45 different components that were interchangeable in 15 cam action mold bases.
  • Provided production molding of all components.

Results

Aztec exceeded all of the customer requirements and has become an integral part of the design team at the inception of new product design.

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Case Study: Marker System for Promotional Advertising

Aztec Tool was asked to develop a triple marker system. We were shown the original product and a non-functioning sample.

Customer Requirements

  • New marker system had to be aesthetically pleasing.
  • Design had to be ergonomic.
  • Marker assembly had to be simple and cost effective.
  • Marker caps had to seal to prevent the ink from drying.
  • Prototype pieces had to be molded in 12 weeks.

Aztec’s Solution

We proposed an insert marker system with universal top and bottom covers. The insert markers could be used in the triple marker system as well as individually.

Project Milestones

  • Created CAD documentation for engineering and customer review.
  • Refined the design for customer sign off.
  • Created STL files to manufacture SLA models for proof of design.
  • Designed and manufactured prototype tooling for all components the project required.
  • Ran prototype parts to assure compatibility at the assembly level.
  • Modified design for full production tooling.
  • Designed and manufactured 4 hot runner multi-cavity molds for production.

Results

Aztec met the delivery and budget requirements. This project was so successful that spin-off products have been developed and higher capacity tooling was manufactured. All tooling and molding was completed at Aztec’s Edgewood facility.

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Case Study: Medical Products

Aztec Tool was approached to reverse engineer several medical products. Aztec was provided with a variety of existing medical products and asked to review them for design and manufacturing improvements.

Customer Requirements:

  • Improve the ergonomic design of the product.
  • Reduce and simplify secondary assembly operations.
  • Redesign and improve molding cycles.
  • Develop prototype and production tooling.

Aztec’s Solution:

Products were reviewed and Aztec supplied the customer with 3D CAD visuals and SLA prototypes.

Project Milestones:

  • Created simplified 3D product design for customer evaluation.
  • Provided SLA and FDM prototypes.
  • Recommended and designed the appropriate tooling based on customer budget and production requirements.
  • Built, tested, and provided pilot production run for new molds.

Results:

Aztec repeatedly met all of the customer requirements and continues to provide on going regularly scheduled tool maintenance along with new product development.

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