Ground Brush box


The customer tried to develop an inhouse solution using different types of materials and designs including phenolic plastic and aluminum.

All the solutions designed by the customer failed prematurely during testing

We were tasks with designing a brass alternative and to maximize the lifetime of the part while minimizing the part weight


  • 30% weight reduction compared to brass baseline
  • 25% cost reduction compared to current production
  • Removed all the previous failure points
  • Streamlined the design and simplified the assembly process