Our client Surefix are on a mission to improve quality and standards for guttering installation with their new Rise and Fall support bracket product (patent pending).
Surefix initially approached the 3D-Consultancy (3DC) to see about manufacturing and supply of their brackets with a particular interest in 3D printing. The approach to 3DC was after they had tried for many months a host of other suppliers. These earlier supplier discussions had all failed to achieve the essential cost and quality targets.
Surefix claim that “The new Rise and Fall Gutter Bracket saves you both time and money while adhering to new health and safety regulations.
The Surefix product solution is faster to install, stronger when in place and safer for site personnel. It has more adjustment and can be easily removed for maintenance.
Unlike the installation method of alternative bracket solutions, the Surefix Rise and Fall Gutter Bracket does not cause damage or cracking to a building’s brickwork, and has been subjected to rigorous industry testing, including pull-out and downward load testing.”
This enquiry to the 3D Consultancy was typical of many enquiries we receive. Our initial investigation into a 3D printed solution would not deliver on the customer requirements. However, our engineering team were able to offer alternative options which do meet the required specifications and the quality and cost targets.
Price point was key for the customer given this was a new product into a very competitive market with established solutions already available. The goal was to deliver a high-quality product that was still price comparable but with the value-add benefits the Surefix bracket brings in terms of superior quality, fit once fit well and fit quicker.
After engaging with 3D Consultancy’s manufacturing partners, a cost viable solution in a stainless-steel material SS201 was selected for a balance of good strength to economy and production samples were created. In parallel, a low cost C45 carbon steel variant was also produced with a significant cost reduction this would give our customer the option of supplying these to lower cost and affordable housing.
Dialogue was now underway with potential buyers and the first sourcing and sample making exercise was turned around in just 4 weeks. These samples were very well received aesthetically, however when pushing the samples beyond the required British Standard there was a bend failure and so further design analysis, and development work was undertaken.
These challenges are typical of what the 3D Consultancy team face and engineering performance improvements were added without adding any cost. The resulting improved C45 and SS201 samples which were supplied within only 3 weeks not only held double the required load they also held the load for over 1 hour (against a required 5 minutes) without any bend failure.
A spokesperson for Surefix commented:
‘’ Working with Brett and the 3D Consultancy to get a prototype made of our product, test on site, adjust and finalise, has been second to none. A very reactive company, hitting all dates and deadlines required and going above and beyond to help get this product finalised ’’.
ABOUT US
The 3D Consultancy are an engineering led design and manufacturing consultancy providing technical solutions utilising CAD digital processes, advanced 3D printing/additive manufacturing, and 3D scanning.
If you have a technical challenge with very tight deadlines that require exacting specifications and an agile working approach to achieve results, then give us a call on 0203 092 4429 or send us an email [email protected] or visit our website for more information.