A few years ago we were contracted to provide design concepts and cost studies for two lines of high speed commercial dot matrix printers. One product line (Cyrus) was serial printers and the other was line printers (Raven). Proposed concepts were supposed to establish a new appearance standard for the company’s entire current and future product lines based on a modular enclosure system.

The proposed system would enable our client to configure any product model by simply assembling the appropriate components for that particular configuration.

Extensive market research, concept development and detailed cost studies were also included in this project to provide our client’s management with a comprehensive information package for making informed decisions.

A summary of design objectives is summarized below:

1. Develop a new line of serial printers with increased speed
2. Reduce the overall cost of new printers
3. Improve overall cost/performance ratios for the product line
4. Maintain or improve overall quality and reliability
5. Improve overall appearance and product line image
6. Develop a family appearance
7. Improve cooling and reduce noise
8. Improve the mechanism/enclosure integration
9. Enhance ease of assembly and manufacturing
10. Increase durability during shipping by minimizing weight and size
11. Improve profit margins by cost reduction
12. Improve operator access to all functions
13. Improve serviceability and minimize field service calls

The case study describes the work we completed during this comprehensive design project.

Phase 1- Information Gathering, Preliminary Layouts and Basic Concepts

The project began with a series of meetings at our client’s facility to review all the design parameters affecting the product line and individual requirements for each printer model. Details can be viewed in a comprehensive HTML report which was presented to our client and updated throughout the project.

During this phase we also imported and assembled 3D CAD geometry of major printer components obtained from our client. These components were rearranged in a number of different configurations to determine the most feasible packaging options for each printer.

Cyrus printer component configurations

Raven printer component configurations

Phase 1 was completed after our client was presented with the product specification report and simplified 3D CAD layouts for each printer, which were later used to develop concepts in Phase 2.

Phase 2. Concept Development, Sketches and Renderings

Numerous concept sketches were developed to explore alternative designs for each printer based on the product specifications and layouts developed in Phase 1.

In addition to sketches, we also rendered selected concepts based on various product configurations to clearly illustrate how the proposed modular system would be adapted to the product line.

Our team focused on designs that provided a foundation for product branding as well as a modular system could be configured for any printer model. These objectives were achieved by concentrating on product details such as doors, louvers, keypads, colors, tractors, and handles which would establish a visual continuity throughout the entire product line.

Phase 3- Design Refinement and Enclosure Design Layout

After Phase 2 was completed, the design was further developed based on a selected concept. During this phase external cover details were more clearly defined based on manufacturing methods, interface with internal components, paper handling, keypads and many other features interrelated to appearance.

Details affecting the enclosure and overall structure for the serial printer line were developed in 3D CAD assemblies as shown in the following pictures.

Similar details were developed in different 3D CAD assemblies based on various design options and cost trade-offs for the Raven line printers.

Raven line printer production design concept 1

Raven line printer production design concept 2

Raven line printer without pedestal

Detailed full scale foam core models for each printer were constructed based to study assembly procedures and serviceability. The following pictures illustrate how these study models were used to evaluate these important manufacturing criteria.

These technical foamcore models were followed by foamcore models of a selected concept derived from a detailed 3D CAD file.

The proposed design was illustrated in its various configurations for each printer model to demonstrate the feasibility and modularity of the proposed design.

In addition, vendors were contacted to obtain tooling costs, parts cost and lead times for plastic and sheet metal parts. Assembly, noise emissions, EMI, testing, and service issues were also reviewed during this phase.

The project concluded with a formal presentation of design concepts and associated costs based on tooling and parts count.