Zippsafe Smart Soft Locker Solution
Metal to plastic – Small hanger
2020
PRODUCT DEVELOPMENT | SIMULATION | PROTOTYPE | MANUFACTURING
The ZippSpace is the world's most space-saving locker solution developed by Zippsafe. Instead of rigid material, flexible locking pockets are used. Thus, Zippsafe has revolutionized the traditional locker and sets new standards with its Soft Locker Solutions. The use of flexible, textile locker bags instead of metal sheet allowing space savings of up to 70% compared to conventional lockers. Moreover, the system is intelligent and user-friendly.
X-Plast was involved in the product development and series production of several parts of the ZippSpace system to create a sustainable and cost-effective future proof replacement for the former aluminum parts, such as the small hanger. Our collaboration with Maform and Zippsafe resulted in truly innovative plastic products.
The most challenging part of the development was to keep the basic contour of the original metal part. Due to pre-approved specifications based on the aluminum part, the new plastic hanger’s mechanical properties also needed to reach similar stiffness levels.
To meet the requirements, we started our process using topology optimization based on FEA simulation to find a suitable geometry, while trying to keep the original design as requested. When we had finalized the part geometry based on these results, although it complied with all requirements, we did not like the result, so we went back to the drawing board and started all over.
At this point, we have decided that instead of simply constraining our designers and simulation specialist to certain requirements and tasks within the project, we bring them together for a workshop to discuss the possibilities. After the workshop, they came up with several sophisticated cross-section possibilities, that could make the part as rigid as needed without adding countless ribs.
This way, we have created a new concept meeting all requirements: fitting the original design language with a brand-new form, mechanically adequate, and perfectly functioning.
Details matter
To guarantee the best user experience for all Zippsafe users, we have added a small flexible component. Using 2K injection molding, we were able to deliver a remarkably silent and precise connection between the metal and plastic components.
Designed to the smallest details, a truly Swiss product, designed and manufactured in Hungary by X-Plast.
