BATTERY CHARGING DOCK
BRIEF
The Dirt MONSTER cordless vacuum is supplied with charging stand. However being a commercial product and only being able to charge one battery at a time creates unnecessary downtime.
The brief was to design a compact dual fast-charging dock that charges two batteries simultaneously, improving efficiency while complementing the existing product range.
Duration 10 months
Start date 2025
Status in production
PRODUCT DEVELOPMENT
The concept and initial CAD took 2 days due to the urgency of the project. This was 3D printed in house and the CAD sent to the manufacture of the Dirt MONSTER to print, test and review.
Texture document
green = A1 gloss finish
red = MID A (YS 1284)
Draft Analysis on each part
REFINING THE DESIGN
The CAD was then adjusted in response to the feedback from our printed model and from the factory. For example;
over heating issue which was resolved with extra rear vents and fans.
tooling issue with top black part. The tool needed to achieve the housing around the battery would be too thin. The solutions proposed where reduce to a consistent wall thickness or make the sides bigger. Both of which would reduce the overall aesthetics. So the part was split into two to retain the appearance.
strength of the front vents which was resolved by partially blanking three of the front vents and adding screw bosses
PRODUCTION CAD
PRODUCTION
First off tool
Initial injection moulded samples were inspected to evaluate dimensional accuracy, cosmetic quality and assembly performance. Minor refinements to gating, surface finish and tolerances were implemented before production approval.
