Case Background
Customer's Products
Customer's Requirements
Difficult Point
Design Solution
Finished Sample Display And Confirmation
Project scoring
Reference Value to you
In early November 2024, a client reached out to AUKE with a unique need for metal trays specifically designed to hold small gears. He is from a German-funded enterprises in China manufacturing auto parts and he is responsible for purchasing. He told us that he had been following our company for a long time and learned that AUKE has been working with his peers for a long time, so he believed we are capable of designing a form-fitting tray for him.
Customer's ProductsSmall gears, with dimensions of 24mm in height and divided into three segments—two symmetrical outer segments and a middle segment featuring a ribbed gear design. |  |
RequirementsOne metal tray capable of holding 352 small gears securely Trays have to be stackable Total weight of the tray＜3kg Easy to lift manually | |
Difficult PointMaintaining the integrity of the gears while providing a robust solution for stackability Ensuring two-thirds of each parts remained uncompressed when stacked upon one another The existing trays in the market either did not support adequate stacking or compromised the safety and integrity of the components being held. Therefore, the client's goal was not only to utilize these trays on a production line but also to maintain efficiency while ensuring the gears remained undamaged during both transit and storage. | |
With over ten years of experience in the industry, AUKE's design team rapidly engaged in brainstorming sessions to address the project's primary complexities.
Dual-layer hollow design
Their proposed solution featured a dual-layer hollow design. This innovative configuration allowed for corresponding hole placements between the upper and lower layers of the tray, ensuring that gears in one tray fit perfectly into the holes of the upper tray. The dual-layer design not only facilitated stackability but also provided enhanced stability for the gears during transportation.
To further support the stacked trays without putting additional pressure on the gears, AUKE added stacking feet to each corner of the tray. This clever design element guaranteed that when the trays were stacked, the bottom layer would not be compressed by the weight of the layers above, thereby preserving the integrity of all contained components.
Enhancing Usability with Embedded Handles
Recognizing the need for improved ergonomics and functionality, AUKE's team suggested incorporating embedded handles into the design of the trays. This idea coincidentally aligned with the clients’ preferences, reinforcing the collaborative nature of the project. The embedded handles would facilitate ease of use, allowing operators on the production line to swiftly move trays as needed—enhancing efficiency on the floor.
The Aesthetic Touch: Galvanized Color Zinc Coating
In addition to functionality, the appearance of the trays played a crucial role in the final product. AUKE proposed a dazzling colored zinc plating for the trays, which would reflect different hues under lighting. This eye-catching feature added a touch of aesthetics that could enhance the representation of the client's brand while ensuring the trays stood out in a production environment.
Material and Design Considerations
The choice of materials was also pivotal in achieving the desired outcome. A 1.5mm thick carbon steel was selected for its strength and durability. The carbon steel sheet was punched with specified hole styles. The precision-hole punching design ensured that the holes for gear placement were uniformly distributed, significantly reducing the overall weight of the tray without sacrificing structural integrity. This careful consideration in material selection played a vital role in both performance and cost-effectiveness.
At AUKE, it is standard procedure to create sample before large-scale production. The design team quickly moved from concept to creation, developing the sample within just five days after the design was approved. Once the sample was completed, it was sent to the client for testing and confirmation. The client received the sample and efficiently tested it within two days, providing the confirmation necessary to move forward. The speed and dedication exhibited throughout the project demonstrated AUKE's commitment to excellence and responsiveness to the client’s needs. Production Timeline Once the design was approved, AUKE established a timeline for mass production that typically spans about a month. The production was carefully organized to ensure that every tray met the specified design criteria. By December 25, the trays were carefully packaged in stretch film, secured with packaging tape, and placed into wooden crates ready to be delivered. |  |
Project Scoring
Communication: ★★★★★
Design Solution: ★★★★★
Quality Level: ★★★★★
Delivery Speed: ★★★★★
Customer Satisfaction: ★★★★★
This project highlights AUKE's capacity to innovate while adhering to client specifications.
By addressing the core challenges of stackability and usability, AUKE was able to devise a solution that not only met but exceeded client expectations. The combination of thoughtful design, high-quality materials, and attention to detail contributed to a product that is both practical and visually stunning.
AUKE's professionalism and dedication to project execution have proven that clients can trust AUKE to deliver effective solutions for different application that optimize production efficiency without compromising product quality. The successful completion of this project exemplifies AUKE's commitment to innovation, customer satisfaction, and ultimately, success.
Final Insights
Moving forward, AUKE will continue to embrace challenges as opportunities for innovation, ensuring that all clients receive top-tier metal storage baskets, steel storage cages tailored to their unique needs. The collaboration with this client serves as an excellent case study illustrating AUKE's innovative spirit, expert design capabilities, and unwavering commitment to quality in every project undertaken.
You can also use the same perforated metal tray design to store your similar parts
Your steel storage baskets/trays/bins can be plated color zinc
Commonly, Your mass order can be delivered within 30 days
