A Practical Approach to Smarter Product Development…
Not every engineering solution starts with high-tech equipment.
Some start with a knife…and an old cardboard box.
Recently, we partnered with a customer looking to reduce costs by transitioning from a traditional metal tray to a plastic alternative. The goal was clear: lower part costs, reduce weight for more efficient freight, and improve overall production economics.
Straightforward in theory — but as with most New Product Development, the reality required a more thoughtful approach.
From Metal to Plastic: The Reverse Engineering Process
The project began with a physical metal tray and a set of measurements. From there, our team reverse engineered the component, developing detailed CAD models and technical drawings to form the foundation of a new plastic design.
But there was a catch.
The trays weren’t used in isolation — they needed to fit seamlessly into a range of existing bins, all with slightly different dimensions. Designing a “one-size-fits-all” solution wasn’t going to be as simple as adjusting a few measurements on a screen.
Getting Hands-On.
Rather than relying solely on digital assumptions, we took a more practical route.
We sourced the actual bins our customer used — ordering them directly to ensure accuracy. Then came the unconventional part…
Using nothing more sophisticated than cardboard (yes, from an old box), we created physical prototypes of the proposed design. These quick, low-cost mock-ups allowed us to test fit, function, and usability before committing to tooling.
It might not look glamorous, but this stage proved invaluable.
Why This Matters…
This hands-on, iterative approach allowed us to:
Identify subtle fit issues early
Refine the design quickly without costly tooling changes
Validate functionality across multiple bin sizes
Give the customer confidence before moving to production
In short, we reduced risk — and saved both time and money.
Innovation Isn’t Always High-Tech
There’s a misconception that innovation always involves complex simulations or cutting-edge technology. While those tools absolutely have their place, real-world problem solving often benefits from simple, tangible methods.
Cardboard prototyping is fast, flexible, and incredibly effective — especially in the early stages of product development.
And more importantly, it reflects a mindset.
The Dudley Associates Approach…
We don’t just design parts — we solve problems.
Whether that means advanced CAD engineering, in-house tooling manufacture, or building prototypes from whatever materials are at hand, our focus is always the same: delivering practical, cost-effective solutions that work in the real world.
Sometimes, thinking outside the box… starts with using one.
Dudley Associates Ltd.
New Concept Development | Toolmaking | Technical Plastic Injection Moulding
Since 1991.
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