SJD Designs.
Design Engineer | NPD Specialist | CAD Prototyping | Sustainability Advocate
SpeedFlex - Compact Cordless Dispenser
Revolutionary Rackless dispensing technology to produce a more compact cordless dispenser.
Project summary:
Revolutionary development of a cordless dispenser featuring groundbreaking rack-less technology for fluid dispensing applications. This innovative project transformed traditional dispensing mechanisms by replacing rigid rack systems with a flexible spring-driven mechanism, resulting in a significantly more compact and portable design.
Timeline:
August 2022 - March 2024
Role:
Product Design Engineer
Patent Filed:
WO2024199936A1
Overview
Problem Statement
Challenge
Traditional cordless dispensers rely on rigid rack systems that limit:
- Compactness and portability
- Versatility across different cartridge sizes
- User accessibility for DIY market segment
Opportunity
Develop a compact, versatile dispenser that eliminates the rigid rack/rod system while maintaining high dispense force capabilities.
My Role and Responsibilities
Design Engineer (2022-2024)
Led mechanical development of the entire motor gearbox assembly, main ring gear, flexible rod system, flexible rod channel, bearing system, and ramp mechanism
Responsible for complex gearing system design and mechanical optimization to achieve 2.5kN output force specification
Developed and managed CAD models for over 250 components across the three-phase development process
Created detailed engineering drawings and specifications for manufacturing partners in China
Led technical optimization and design for manufacture (DFM) initiatives to transition from prototype to production-ready designs
Project Scope and Responsibilities
Highly Compact - An initial ideation of being the lightest and most compact for tight spaces. Developed creation required compactness for mobility and specialised environments.
Competitive Output Force - Achieve dispensing forces of up to 2.5kN using advanced mechanical and electronic subassemblies.
Dispense Adaptability - Enables dispensing from multiple container types and sizes including foils, cartridges and sachets.
Improved User Experience - An ergonimic design with digital LCD controls and multiple replaceable and serviceable subassemblies and parts.
Technical Process
Phase 1: Concept Research and Ideation
Innovated a new rackless cordless dispenser concept, focusing on compatibility with sachets, foils, and cartridges.
Generated and assessed over 20 conceptual schemes for drive mechanisms, flexible rods, and gear layouts.
Phase 2: Prototype Development and Validation
Developed and tested several proof-of-principle rigs, experimenting with different gear and drive spring arrangements.
Conducted ergonomic and weight distribution studies to optimize usability for various cartridge configurations.
Built multiple functioning prototypes, validating the mechanical design through high-load, life, and safety testing.
Phase 3: Technical Optimisation and DFM
Transitioned the design from prototyping-focused structures to injection-moulded, die-cast, and CNC-manufactured components for production.
Optimised bearing, gear, and frame designs for both robustness and manufacturability, using engineering simulations and fixture trials.
Ensured all parts adhered to manufacturing tolerances and documented thorough quality control specifications for suppliers.
