Project

Electrode Block

A magnetic mating feature that improved the reliability and ergonomics of an electrode block, while cutting cost per part.

Magnetic Mating -$400/Part Ergonomic Redesign
Electrode block CAD model
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Problem

The existing electrode block was unreliable to mate by hand and carried unnecessary cost, calling for a redesign that improved ease-of-use while reducing cost per part.

Electrode block prototype 1
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Action

  • Improved reliability of the dual-component electrode block by implementing a magnetic mating feature between the two halves.
  • Calculated the optimal magnetic strength to balance ease-of-use for the operator against unwanted separation during use.
  • Redesigned the block with ergonomics in mind, integrating a guiding feature to make correct alignment intuitive on the second prototype iteration.
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Result

  • Reduced cost by $400 per part through the ergonomic, magnetically-mated redesign.
  • Improved the reliability and ease-of-use of the electrode block for operators in day-to-day use.
Electrode block CAD model
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