In the world of product design, the glamorous appeal of industrial design often takes prominence. We envision sleek forms, intuitive interfaces, and innovative functionalities. However, the real innovation is sometimes hidden behind the scenes, not just in what is designed, but in how it’s made and from what. The strategic selection of materials and manufacturing processes can profoundly impact a product’s performance, cost, aesthetics, and even its very existence.
Every design is constrained (or liberated) by the realities of its production. A brilliant concept can remain just that – a concept – if the chosen materials or manufacturing methods aren’t realistic, or if they render the product uneconomical or impractical. Conversely, a fuller understanding of these elements can inspire new design avenues, overcome technical challenges, and create genuinely superior products.
This powerful connection can be seen in the dynamic relationship between:
A good designer will consider these factors in tandem, from the earliest stages of any design project.
Kwikscreen specializes in innovative hospital privacy screens and infection control solutions. Their products are designed as a more hygienic, sustainable, and cost-effective alternative to traditional hospital curtains. KwikScreens feature minimal dirt traps and a single touchpoint for targeted cleaning, significantly reducing bacteria buildup. Beyond hygiene, they offer remarkable flexibility, allowing hospitals to easily create temporary bay spaces, and can be readily transported and deployed throughout various departments.
Kwikscreen’s commitment to innovation and drive for perfection led them to one area for potential improvement: the feet for their screens. Production products use a thick sheet metal base which initially proved expensive and heavy effecting their portability. Beyond these practical concerns, Kwikscreen aimed for a more premium look and feel, reflecting the high quality of their overall product. Key functional improvements were also sought: the ability for screens to nest efficiently when stored, enhanced ease of cleaning for critical hygiene environments, and a more robust design achieved by moving the fittings further up the main body of the screen. This comprehensive brief presented a clear opportunity to demonstrate how a fresh perspective on material and manufacturing choices could unlock a superior solution, turning design constraints into innovative possibilities.
One might initially think of welded steel, injection-molded plastic, or sheet metal fabrication. Each has its merits:
After careful consideration of the brief’s requirements and the limitations of alternative manufacturing methods, we opted to pursue Sand-Cast Aluminium for the Kwikscreen feet. This decision was driven by the numerous benefits this specific material and process combination offered, aligning perfectly with the goals of achieving a premium aesthetic, reducing weight, improving functionality, and maintaining cost-effectiveness for the required production volumes.
Imagine building a sandcastle on the beach with a bucket. You pack wet sand into the bucket (your mold), turn it over, lift the bucket, and voilà – you have a sandcastle (your cast object).
Sand casting works on a very similar principle, but on an industrial scale with precise controls:
This process allows for intricate designs, hollow sections, and the ability to form undercuts, making it ideal for creating complex, single-piece components.
The choice of sand-cast aluminium for this project was driven by the advantages of the sand casting process. This versatile manufacturing method, especially combined with aluminium, offer a combination of benefits that make it the ideal solution to address Kwikscreen’s specific design and functional requirements.
By opting for sand-cast aluminium, Mouse were not just selecting a material and a process; they were embracing a combination that enabled a foot design that is simultaneously strong, stable, durable, and visually distinctive, all while meeting economic production targets. The organic shapes and integrated features inherent to casting provided a functional and aesthetic solution that would have been significantly more challenging or costly to achieve with other methods.
Whilst this new design made it through the tooling phase and into the first production batch, testing unveiled some unexpected results. The perceived excessive weight of the original steel bases actually provided more stability than previously tested. Furthermore, the higher assembly points and integration of the new design unexpectedly affected the product’s overall functionality. Lastly, the high leg design, intended for improved cleaning, inadvertently added a perceived trip hazard. While all of these challenges could potentially be overcome with further design iterations, a business decision was made to continue with the existing sheet steel foot for the time being.
However, let’s look at the positives: due to the chosen manufacturing process (sand casting), this entire design development and exploration came at minimal cost. The flexibility of sand casting allowed for rapid prototyping and testing without significant investment in expensive permanent tooling, proving the value of exploring manufacturing alternatives even when the initial direction doesn’t become the final product.
The Kwikscreen feet demonstrate that material and manufacturing choices are not mere afterthoughts in the design process. They are fundamental pillars that support and shape innovation. Engineers and designers who understand the landscape of materials and the manufacturing processes are best equipped to unlock new possibilities, transform concepts into realities, and ultimately deliver products that excel in performance, aesthetics, and economic viability. It’s a powerful reminder that true design brilliance often emerges at the intersection of creativity and manufacturing know-how.
Find out more about Kwikscreen
Read more about the project here
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