Project: Festool Multitool
Disciplines: Product Development
Client: Festool (Conceptual)
Year: 2017

 

Product Development: Kevin Shek

Design For Manufacturing

This university assignment was to develop a screwdriver for manufacturing, including with cost quotation, 2D drawings, and packaging. The feasibility was supported by the cost quotation that was linked to a choice of impact-resistant materials and the production method of the fully finished product.

The Festool Multitool is a lightweight screwdriver for professional mountain bikers. The concept was designed to fulfill the gap between the traditional and electric screwdriver for traveling and extreme circumstances. The Festool Multitool is highly impact-resistant and designed for intensive use.

 

Requirements

The tool represents the brand experience and appearance of Festool. The maximum retail price is €20, with a manufacturing price €5. The client CMK B.V. expects to produce 50,000 pieces per year. The tool processes large mechanical forces, so High-Performance Plastics can be very suitable.

 

The Target Group

The target group are professional mountain bikers and bike fanatics. They use high-quality products to maintain their bike often and that’s why maintenance tools must work well.
The user don’t carry too many (heavy) things while cycling. The problem is that traditional screwdrivers are not space-saving, because you need several separate screwdrivers for each kind of screw and the electric screwdrivers are mostly too heavy and not suitable for on the go.

The Ideation Process

I started with a brand research to define the appearance of Festool. During the sketching phase, I searched for ergonomic shapes and textures to create more grip while using the screwdriver. I have made several foams sketches for this. The final shape looks like a drill machine, however, the handle functions as a lever to exert more force during use. The tool had been tested with the user and with the general ergonomic hand sizes of DINED.

 

Cost Quotation and Manufacturing

All the manufacturing requirements, such as Injection Molding had been taking account during the 3D modeling phase. For example, materialization, molding feasibility and injection cycle per part.

The financial calculation is included in the cost of materials, machinery, transportation, procurement parts, assembly, and insurance. The location of the manufacturing process depends on the size of the badge. I advise to produce it in within Europe, such as Poland to reduce overseas transportation and insurance cost.

The total weight of the tool is 300 grams with a manufacture cost price of €3,55. The retail price is €15,99 including with transport and packaging cost.

Specifications

The multitool contains four kinds of hardened steel screws, such as Torx 25/30, Inbus 4/5, and cross -and flathead screws. This can be stored at the back of the tool.
A common problem of traditional screws is that your wrist becomes painful during heavily repeating the rotating movement.
The inner mechanism helps the user to screw easier without a painful wrist by reducing the rotating angle (less than 45-degree). With the shift at the side, you can adjust the rotating direction if you want to unscrew or left-handed. There is also a Micro SD Card storage for GoPro users.

Impact-Resistant Materials

The blue parts functions as a grip surface that is suitable by wet weather. The green parts shows settings of the product, such as replacing the screw bits or shifting the rotation direction.

The black and green parts are made of Polyamide 6 with 30% Glass Fibre. The advantages of PA 6 are high mechanical stiffness, good fatigue resistance, and excellent wear resistance. The blue parts are made of TPE-E (Thermoplastic Elastomer) and this will be merged with Polyamide during the 2K Injection Molding process. The advantages of this material are high-impact resistance, flexibility (grip) and color options. I chose for maximum two kinds of plastics to ensure the quality and the reduce the price for manufacturing.

 

Parts

The final design consists 12 parts, which 5 parts are purchased to reduce cost. It does not contain any glue or other chemical connection for repair and environment purposes.

Injection and 2K Injection Molding

Injection molding is very suitable for producing multiple complex products. It’s a cost reducing production process for large badges (10 000 plus). The notches at the top of the black parts is to ensure the connection between PA 6 and TPE-E materials.

Crystal Plastics such as Polyamide need a wall angle of 2-degree at a melting temperature of 250 – 285 C, Mold temperature of 50-80 C, and a cycle time of 30 seconds.
Multiple cavitations will help to produce faster at a time, like 6 products per cycle.

 

Mechanism Assembly

The mechanism will be pressed into the body parts. In particular, the inner ribs are resistant to the large mechanical forces while using the tool. This also does not contain any glue or screws to connect.

Testing

The final parts were succesfully tested with an injection molding company in Amsterdam. 3D printing was also used to test the manufacturing feasibility of the product. Even after the first test, the design had to be optimized for the machinery tolerances, and this is why it’s a time consuming process.

 

2D Drawing

The final design was documented in 2D drawings with all manufacturing details, tolerances, and assembly process.

Transport & Packaging

The final products will be transported on (euro) pallets that approximately fits 5000 pieces on each pallet. The tools are going to be packed per 100 pieces in large boxes for wholesale. In total, 10 pallets are needed for the entire production (with minimum air transportation).

Copyright ⓒ 2018 Kevin Shek. All right reserved.