Design for manufacturing
Industrial Soft Starter Redesign
A production-focused redesign of an industrial motor soft starter that dramatically reduced enclosure size, weight, part count, assembly effort, and material use.
Portfolio archive
Visual case study
Overview
From problem framing to a resolved design.
The redesign for Alvand Madar focused on the enclosure and internal arrangement of an industrial motor soft starter. The previous architecture contained significant unused volume and a high number of fabricated enclosure parts.
By reorganizing internal components and simplifying the sheet-metal architecture, the new enclosure became substantially smaller, lighter, faster to assemble, and less material-intensive while retaining the required product functions.
Packaging the electronics
The redesign began by mapping wasted space and testing new internal layouts. A tighter arrangement reduced the envelope without treating the enclosure as a purely cosmetic shell.
Design for manufacturing
The enclosure was simplified from 36 small and large pieces to four primary pieces, reducing cutting, bending, raw-material consumption, assembly operations, and opportunities for production error.
Prototype to production
Prototypes were used to validate fabrication, coating, printing, fit, assembly sequence, ventilation, access, and the transition from CAD to a manufacturable product.
Continue
View all projects →