Case Study: Assembly Tray for Dog Collars 

Case Introduction

The client for this project produces a dog collar tray for K9 units and military dogs that are customized for each order. The method they were using previously was inefficient, leading to higher production costs. 

Our client had been using store-bought small trays that were not easy to keep together or the correct size. They needed a tray that had individual compartments for each order and could also hold several orders at one time. The tray would move along an assembly line as pieces were added to each order as needed. Additionally, it needed to hold 10 small orders and have a compartment in the center that could hold a larger order.

ShapeMaster’s Design Process

First, we had to determine the size required for each compartment. This dictated the overall size of the tray and the mold needed to form the tray. We then decided that the mold would need to be made of aluminum because of its size.

In order to remain cost-effective, we had the mold cast instead of machined. Then, drawings of the mold were made and sent to a casting company. When we received the mold, it was polished and mounted on a base for forming. Once molded, the tray was trimmed to size and shipped to the client.

Solution

We were able to find the most cost-effective method to mold the trays. This allowed the client to place a smaller order keeping the cost down per tray. Our solution was a multi-cavity tray with thick ABS plastic making for a very rigid solid strong tray that will eliminate the use of the smaller store-bought trays.

We chose ABS black plastic in a utility grade as this provides the most economical cost while delivering on durability and fast forming with quick cycle times in our forming machines.

One thing to always consider is the volume of parts a job will require. This project is large, heavy gauge (thick plastic), and durable yet only 50 trays were required to meet the need of the customer. By using a mold or tool that is machined and made without liquid cooling we were able to provide a reasonable setup fee for this tool with relatively quick cycle times in the molding process, enabling our customer to receive the product they needed, while remaining cost-effective.

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