Typically, we follow a process of developing products from start to finish, crafting visual representations based on production internal components, thereby easing the transition to manufacturing design. Yet, clients sometimes bring their own ideas or concepts, and we assist in realizing them. When FLO® approached us, they already had a clear visual concept in mind for a range of multiple electric car chargers. Our mandate was to find a way to fit everything inside the design without altering the internally pre-approved design intent.

When tasked with designing a product like this, it's essential to account for various external factors that could impact its integrity. These include considerations such as high voltage, extreme temperatures, heavy snow, freezing rain, high-speed winds, impact resistance, etc. Meeting requirements like NEMA Type 4X enclosure or IK10 entails selecting appropriate materials and manufacturing processes. Attention must be paid to details like designing effective gaskets and seals. Given that these products are used daily and require exceptional reliability, thorough decision-making and testing are imperative.

The initial individuals interacting with the product are those assembling it, followed by those involved in installation or maintenance. These workers handle the product extensively for multiple hours each day, making their experience crucial. This is why our product design prioritizes aspects like ease of assembly, space for internal maneuvers (when we can), consideration for configuration adjustments and determining access points ensuring that they don't inadvertently introduce moisture or dirt into the product during maintenance. Ideally, they'll notice and appreciate FLO® 's thoughtful approach to their work.

While developing the holster design, we found it vital to move beyond drawings and conduct practical tests. We had to understand how the user and the product behaved during the insertion and removal of the connector. In the realm of design, certain aspects are subjective, such as aesthetics or weight. In this case, the primary concern was identifying the angle that provided universal alignment. To address this, FLO® assembled about 50 employees to test multiple prototypes at different angles in a room. This process led to the selection of the most comfortable and optimal holster angle.

The aim was to create a product line using different manufacturing processes: some with full injection plastic configurations, others with aluminum die-casting. While these processes share similarities, differences in design details such as fixtures, structures, draft angles, wall thicknesses, surface finishes, and painting processes had to be considered. Despite these differences, all products had to perform equally during testing. FLO® now offers plastic and aluminum housing alternatives, allowing them to provide clients with qualitative and budget-friendly options.

Product line development automatically increases project workload. Designing elements for one product often affects another. For example, when we adjust the mounting location of a circuit board in Product A, it influences the mounting points on Product B. Consequently, modifications to the access holes in Product B are required, which, in turn, affects Product A, ensuring alignment across the entire product family. At the peak of the project, we had a group of five designers to ensure parallel design processes to identify interdependencies and minimize potential regrets and surprises.

In our DETAILING phase, we applied Geometric Dimensioning and Tolerancing (GD&T) to all products within the FLO HomeTM product line. GD&T serves as a system for defining and communicating engineering tolerances for parts and assemblies, outlining acceptable variations in form, size, orientation, and feature location to ensure precise production that meets functional needs. This method establishes clear expectations for vendors, minimizing delays, costs, and conflicts between clients and vendors during production, and fostering a stronger designer-manufacturer-client relationship.

We take great pride in our work and the quality of service we provide to our clients. While all client constraints and requirements are reflected in the visual and mechanical designs, it is crucial that these designs are effectively translated into production. Advanta puts at their clients' disposal a team of independent, talented, and dependable manufacturers to ensure a production at the quality level we strive for. Just as we did for FLO® we can assist you in finding the right vendors who will deliver products of the highest quality to match our design excellence.