Having analysed the design requirements for the new parts in depth, Eaton decided that some would require prototyping. Having already used Rapidparts for a number of previous quick turnround injection moulding projects, Eaton found this an easy choice.
“Rapidparts said they would start machining rapid injection mould tooling immediately, and could provide parts in the actual design material (polycarbonate) within 15 days,” explains Eaton’s quality support engineer.
“We had tried rapid prototypes produced using stereolithography (SLA), but because of the material you don’t really get a true feel for the functionality of these components. Using the service provided by Rapidparts we could give the parts a proper ‘form, fit and function’ test, including strength testing.”
Rapidparts prototyped the three main mouldings required for the new grid switch modules. These were a base which houses the metal contact parts, a cover that fits over the base, and the internal rocker. A small quantity of around 500 of each part was supplied and “worked very well” according to Eaton.
“There was a problem when one particular switch wasn’t functioning correctly,” says Eaton’s spokesman. “However, we talked to Rapidparts and they quickly made a clear polycarbonate version so we could observe the switching mechanism in action.
"This revealed that one of the terminals wasn’t bedding down properly, so we made a small design change to compensate. Ultimately it’s far cheaper to make changes at the prototype stage that when in production.”
By way of additional benefit, having prototypes in polycarbonate also allowed Eaton to prove its laser marking process. The new range of Eaton electrical accessories is currently being launched in the UK.
The company’s current products are used in blue chip projects worldwide, including Heathrow Airport Terminal 5 and London's Canary Wharf.
