Energy Monitor

The client manufactures equipment to monitor the energy use of businesses. They had developed a state of the art electronics system utilising an innovative PCB assembly which they now required housing in a custom injection moulded enclosure. The styling of this enclosure had to reflect the importance of this new generation of products as their flagship product range. The client required two versions of the top cover so that it could be branded for two separate commercial markets. The enclosure would also need to capable of mounting onto proprietary bus bar rails found inside large control cabinets as well as being wall mounted with screws and plugs.

Hillside Design developed an injection moulded enclosure which allowed for various configurations of input/output sockets and connections. The client required a number of cosmetic and functional prototypes throughout the process in order to demonstrate the new products, prepare marketing brochures and review aspects of compliance with recognised test authorities. Hillside Design prepared several CNC machined prototypes which were painted and printed to meet these requirements.

The prototypes were used to validate the product ahead of manufacture and were key to evaluating all the different versions of connectors that could reasonably be expected in use worldwide.

Hillside Design maintained a continuous implementation of adjustments between the electronic and mechanical elements during the development stage of the project and were able to minimise any potential delay before toolmaking could begin. Hillside Design and the client had already identified an offshore toolmaker and injection moulder at a very early stage and they were kept abreast of the programme. They were therefore able to begin toolmaking without delay. Although the toolmaker was in a different time zone we supported them with 24 hour availability and provided responses within the hour.

The toolmaking and sampling schedule went according to plan with only minor surface finishing issues having to be solved before a sign off for production was given. Finished parts were shipped and available to coincide with completed electronics assemblies, packaging and branding which resulted in a fully built product being ready in plenty of time for launch.