Design > Project Manage manufacture > Assemble > Deliver
We were approached by the premier supplier of spares for the venerable Austin Seven to Reverse Engineer Die-Cast Brake Shoes and to oversee manufacture of 1500 items. The requirement also stipulated that original design Stainless Steel Wear Plates be manufactured and fitted, leaving the riveting on of Brake Linings to be carried out by our customer.
To enable a vehicle to stop, where do you start ?! We were provided with an original, used sample and the associated mounting items. Our scan of the sample was imported into CAD so that a model could be created, coupled with a technical drawing. The method of manufacture being new to us, we spent time researching a suitable supplier and submitting the model and drawing for quotation. In parallel, and as a sanity check prior to committing to new Tooling for producing the Die Castings, we 3D Printed a sample Brake Shoe for our customer to mount up to a car to check fit and functionality – the Print was robust enough to enable them to attach Brake Linings and operate the braking system in the workshop. Once signed off, we could confidently press ahead with Tooling manufacture and the supply of samples, this time to be put through their paces on the road. Road testing confirmed the provenance of the new items and volume manufacture and assembly could begin.
It was very satisfying to receive a delivery of 1500 pristine Brake Shoe assemblies and to reflect on the logical and sensible steps taken to get to that point, seamlessly and with good cooperation between all parties.