The Royal Air Force
A practical case, as compact and light as possible, dirt-resistant, must withstand a beating and be dust- and waterproof. These were the requirements set by The Royal Air Force for a new case for their F16 maintenance tools. Of course, we were also challenged to help think of other functionalities that would exceed the features of their old case. The result? A sturdy case that meets all the needs of the F16 mechanics. But how exactly did this process go within Faes, from demand to physical product?
Application and wishes of The Royal Air Force
Faes was asked to develop a case for Defense, to easily and safely transport maintenance tools and spare parts for the F16s. This DMC kit, including calibration tools, had to be able to be used directly ‘in the field’. So, as you can probably imagine, there were quite a few requirements for the case. For example:
- The case had to be easy to clean (and keep clean), such as after use on muddy surfaces or in bad weather.
- To be quick and easy to pack and unpack; so it had to be immediately clear which place a particular part had in the case.
- The contents had to be stored in the most structured and compact way possible.
- Extra space in the case to store additional material or parts.
- Easy to store on “the shelves” and recognizable to quickly find the right kit.
The DMC F16 kit: from idea to design
The moment all requirements were mapped out by our packaging expert Henk, he took the old (heavy) steel case to our business office; the engineering department. Here, product engineer Luuk Gijsbers neatly measured all recesses in the interior with the most advanced measuring techniques. Based on these measurements, he designed a new interior design with an optimal layout. He also actively listened to the client’s other wishes and created a case design based on these functionalities. As a first step in the design process, Luuk made a sketch with accompanying calculation. After the customer’s approval, he converted the sketch into a spatial design using our 3D CAD program.
The functionalities of the DMC F16 maintenance case
- We chose a sturdy, quality suitcase that can definitely take a beating.
- The case interior was fitted with two foam shelves, which fit into the case in any order. Two sturdy straps make them easily removable.
- The interior foam in the trunk was “laminated,” making sand, mud and other debris easy to remove.
- The foam is composed of two layers, a blue bottom layer and a black top layer (coated with an attractive carbon film). Then the shapes were milled out, turning the bottom of the recesses blue. That way, the mechanic can see at a glance if any parts are missing and where they should be stored.
- When the lid is opened, packing instructions can be seen, with numbered parts list. By means of a hinge, it is easily opened, giving the mechanic access to extra space in the lid (with “member organizer”), which in this way is well utilized.
- Finally, the case features the printing: DMC Kit, which is placed near the handle, among other things. In this way, the kit can be quickly and easily recognized in a warehouse or workshop.
From design to product
After we presented the 3D design to the customer, and they gave approval for production, any missing materials and parts could be ordered, such as; metal parts, bolts, nuts and hinges. The order was then scheduled into production.
For this project we drew on all our knowledge, experience, creativity and empathy. It shows that optimal cooperation between our consultants, engineers and production is essential.