Trient approached Solid Design Solutions (Solid) with a problem they were having in their production process. They wanted to improve their production process by increasing output and eliminating operator error. The machine Trient envisioned would apply double-sided tape to five sizes of corrugated cards with minimal operator effort.
Trient approached the team at Solid to help create a tape applicator that improved their production process. During the Concept Phase, Solid assembled a project team consisting of a mechanical designer and a controls expert. Together with the client, the team completed a thorough review of the current design and the project objectives. They worked to identify/clarify design specifications required for the machine in order to meet the client’s needs. Conceptual options for achieving the desired performance were developed and refined to finalize the approach to pursue in the following phases.
Once the Concept Phase was complete, the Solid Team moved into the Proof of Principle Phase. In this instance, a prototype of the tape mechanism was built to test the concept and ensure the core assembly of the machine performed in the manner it was intended. The prototype was then incorporated in the final machine. The objective of the Detailed Design Phase was to prepare the design for the Build and Test Phase. To meet this objective, the Solid Team refined the concept selected in the previous phase based on client direction. During this phase Solid wrote the controls program for electrical tests, created fully detailed mechanical 3D solid models and virtual prototypes, and finalized selection of standard off the shelf components to be modified.
During the Build and Test Phase, Solid created and submitted purchase orders for components and required services. Then, using engineering drawings, the received components were inspected and verified. When the components were verified and assembled, the machine was tested. Once the machine passed internal testing, the client reviewed and operated the machine, and an Factory Acceptance Test (FAT) was performed. After the machine passed the FAT, the client accepted the machine.
The result of Solid’s Machine Design and Build Process yielded a tape applicator that applied double-sided tape to multiple different sized corrugated cards with precision and reduced production time by half.