Cambridge Consultants: Designing for hostile environments

The prism 200 is a lightweight, durable and highly sophisticated through-wall radar designed by global product development firm Cambridge Consultants. The company asked us to produce prototype case works for the device. 

The final product needed to meet the appropriate IP rating and environmental testing, including a drop test. Collaborative design development gets results, and experiments done in-house and with the client resulted in a material that would be our best chance of achieving the specification requirements. 

We then embarked on the first set of vacuum-cast case sets to prove the design, the manufacturing materials, and the process. SLA masters were produced and finished to the agreed surface textured finish, and then fit checks were done with the client’s team. Finally, we created the silicone tooling, the final vacuum cast productions were produced, and the device was ready for destructive testing. 

The tests were generally successful, although they uncovered evidence of weakness. We strengthened these areas in our casting process with an over-moulded glass matt reinforcement. 

With this final change, the product was ready for low-volume production in our facility and onward to the hostile environments in which they were destined for use. We have produced case sets numbering into the low hundreds: a real success.