The client is a manufacturer and supplier of concrete reinforcement solutions. The product is a 'pile cage spacer' which is used in the construction of reinforced foundations. The spacer ensures that there will be a sufficient amount of concrete encapsulating the pile cage reinforcement steel. The client had set a very strict budget for tooling and part price because this market is already oversubscribed and very competitive.
The part design had to be optimised to ensure best moulding practise without compromising strength. Hillside Product Design prepared 3D CAD data for two sizes of spacer, which were prototyped using the in-house 3D printer.
Liaison with the toolmaker began at an early stage to ensure that the materials used would meet the weight and performance requirements of the product and that the part design and tooling configuration would meet the requirements of the client.