Medium Batch Production

For this production size we chose to use a combination of metal extrusion parts and a composite laminate.

 The plate will have the same general dimensions.
Width: 40 / 80 mm
Length: 200 / 400 mm
Height: 300 mm

The plate consist of a laminate structure with 4 extrusion parts (2X part B, 2X part C )
The laminate plate has a 90° corner and different cut-outs as seen in the sketch.

The extrusion parts and laminate will be connected to each other by bolts and nuts. This a strong connection and the user can build the structere so there is no need for a mechanic in the production process to put everything together.

Laminate:
-Epoxy resin.
Pro:
Good for mechanical use. There is no direct movement of the parts but the plates have to be able to hold the weight.
High resistance against environment. The toolbox will be used outside and be moved around a lot.
Electrical insulator. It will be used in a high electrical environment.
Low shrinkage. the holes and cut-outs must have a minimal tolerance to fit as good as possible.

Con:
High cost.

-Aramid fibres.
Pro:
Strong/ high stiffness. the box will have to be able to carry the weight.
Low mass. The tools needs to be transported, lower weight is better for the user.
Electrical insulator. It will be used in a high electrical environment.

Con:
Weak against UV light.

-Direction
Bidirectional layout.

-Surface finish against UV light.

-Laminate layout:
45/0/0/45

Extrusion parts on top of the plate. These will be made out of Aluminum. These parts have the same function as the leather connector on the DIY box.
There will be two extrusion parts added to either side connected to the plate by bolt and nut.

On the back there will also be two extrusion parts these will fit in the front of the previous plate. Here we will also use bolts and nuts to connect the extrusion parts.

The handle part. This will be made form the same laminate. but with a different layout. Because it will have a smaller tube shape in the centre. So the user can hold on to it.
We are also looking for the option of making it not symmetrical. So the handle part can be smaller.

To make sure the box is electrical insulated it will also be needed to cover the metal parts in a plastic coating. This is an option we keep open for now because we plate is self is not conductive.