Machine Design / Manufacturing

IO Link

Streamlining Industrial Networking

Solid was asked to design and develop a unique, compact, and user-friendly housing for the latest technology in industrial controls data sharing.


The missing link

IO Link is quickly becoming the manufacturing industry’s standard protocol for industrial data communication. The problem is how to facilitate the exchange of data between sensors and actuators. Comtrol Corporation – an industrial networking company – sought to make a gateway controller that would reduce maintenance and cabling costs while still offering a complete set of network management tools.


A better gateway

Working with the Comtrol team, Solid began identifying the important requirements needed to ensure that the controller performed with efficiency and was easy to use. Technical details were discussed and concept sketches were made. Then, it was on to a 3D CAD model so strategic design and manufacturability trade-offs could be explored. Prototypes were made for assessment and testing to make sure that manufacturing requirements were being met before the final design. Finally, Solid worked closely with the contract manufacturer to design assembly and potting processes as the design was prepared for mass production. Solid also provided the assembly fixtures necessary for production.


In complete control

The result was the Comtrol IO Link Master 4-PNIO. The streamlined IO-link gateway offers many advantages to other gateways of its kind, including: fully potted assembly with nine major enclosure fenestrations, 13 insert-molded light-pipes, high-visible port labeling and LED activity indication, and user “write-on” replaceable tags.

Project Details

What We Did

  • Gateway Controller Housing Design

  • Conceptualization

  • Product Concept Development

  • Prototyping

  • Design for Manufacturing

  • Detailed Design

  • Selection of Contract Manufacturers

  • Final Inspections and Testing

  • Assembly and User Instructions

What We Used

  • Industrial Design

  • Manufacturing Engineering

  • Mechanical Engineering

  • Electrical Engineering

Let's make it happen

Ready to get started with a project? Have questions? Let's talk. That's the first step.

Work with us

"Their designers and engineers worked in close cooperation with our engineers, producing a unified product design that is now in full production. We are very pleased with the results of our collaboration with Solid Design Solutions and recommend them to anyone needing industrial design services."

Steve Erler, Director, Engineering Comtrol Corporation

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