Incase

The Process Behind the Perforation

Our friends at NOTCOT recently posted a feature about the design and development of our new Perforated Snap Case, so we thought we’d share the expanded version of the conversation with Joe (Chief Design Officer) and Markus (Vice President of Design) here. Visit NOTCOT to enter their giveaway of our Perforated Snap Cases, but don’t wait too long–they’re picking a winner on Friday, December 11.

What inspired you to create a perforated iPhone case?
The Snap Case (non-perforated) form factor is our lightest, most minimal case in our iPhone case product lineup. The inspiration for perforation stemmed from the idea to further minimize the case by reducing weight without taking away the functional aspect of it being a protective solution.

The first idea that came to mind was using a simple, geometric pattern. From there, we started exploring how to perforate our Snap Case with different shapes, scales and pattern densities, pushing the limits of what is possible to manufacture.

Describe the design and development process for the Perforated Snap Case.
At the start of any product development process, we begin with a team brainstorm session to generate as many ideas as possible. From there we narrow it down to the most promising concepts and refine them with sketching and rendering. Once an idea is committed to, the design team builds a 3D CAD model, which serves as a database to create Stereolithography models, a prototyping process that enables us to print a desired shape in 3D.

Next, we test the prototypes and further refine the geometry. A final design is then agreed upon and we analyze and study its geometry to determine manufacturing feasibility. Once a product passes this stage, the tooling process can commence.

To start the tooling process, we begin with large blocks of steel and machine out the negative shape of our case to make a hollow form that is later injected with polycarbonate material. Because of the all-over perforated design of the Perforated Snap Case, the tooling process is very intricate and takes a relatively long period of time to accomplish. Individual steel pins with varying degrees of curvature for each hole are needed to create the perforated design.

Once the tool is cut, it is then textured and finished. Following this stage of tooling, we shoot the first test shots in plastic, which help us to further debug and finalize the tool as well as the injection settings to create the perfect molded part for the production run.

What types of engineering challenges did the Perforated Snap Case pose?
Injection molding makes it relatively easy to perforate a pattern in one direction, but for the Perforated Snap Case, we were challenged with wrapping a pattern evenly onto a surface that contains multiple directions and very thin wall sections. Our goal was to keep the perforated pattern aligned regardless of the angle from which it is viewed. Because of the curves of the case, it became rather challenging to determine the best way to mold it.

Our product development process is one of continual refinement—we go through many prototypes and trials in order to find the one that will work best for manufacturing.

Please describe the intricacies of the tool and the mold injection.
For the injection molding process, we use hardened steel tools that are the negative (or hollow) form of our case. These are necessary for the mold injection of plastic that creates the positive case form.

Thin steel pins within the tool create the intricate perforated pattern of the case. When in production, injection-molded plastic flows under high pressure and temperature in between the pins. The challenge is to find the perfect balance—the pins cannot be too small, since that would cause them to break under high pressure; and the spacing cannot be too dense, as material needs to flow through the mold easily and evenly.

Since the perforated pattern runs throughout the case, multiple complicated tool actions are required to achieve a consistent pattern.

How many holes are in the case?
Nearly 1000.

Are there benefits to using this case over another iPhone case? How does it differ from other cases on the market?
Our Snap Case is our most minimal case and provides just the slightest elevation around the bezel, which allows the iPhone widescreen to be raised above a surface while it lies on its front face. The design of the Perforated Snap Case gives a unique surface texture, resulting in a better grip because of the pattern. And of course, its perforated design adds visual interest as well.

SF Studio First Glance

Lately I’ve been working with the group on the final touches of our SF design studio. It’s been quite a process to produce this unique space and I wanted to give you a first glance into our new home in the bay.

Our custom conference table. A shaped piece of solid corian that was so heavy they needed to bring it in through the window via crane.

The custom dj booth. A bunch of the guys here are dj’s, so it only made sense to make this the lounge centerpiece.

You can check out a few more pics here. More images and info on the space and the people behind it all to come.

HIGHMATH

I finally received the latest Arkitip issue today. No. 0044 HIGHMATH. This time around, the magazine handed over all design responsibilities to Wood Wood, a Danish design collective. “Produced on the occasion of exhibition,” the issue also served as a working catalog for the self titled show being held in Berlin featuring an incredible group of creatives.

I’ve always been impressed with Arkitip’s ability to create a refreshingly new experience with each of their issues. For issue 0044, each magazine is packaged in a custom box commemorating the show in Berlin along with a 3D viewer and 3 image reels containing work from the exhibition.

Also featured in this issue is my latest ad showcasing our Nylon Backpack.

Be sure to check out more pics from the event in Berlin on the Arkitip Intelligence blog. Stay tuned…

Anuncios publicados en las revistas “Clínica Rural” y “Glosa”

Announcements published in the magazines “Clinical Rural” and “Gloss” Years 50-60-70. That’s what google translate made out of it, but basically it’s a gorgeous set of old Spanish pharmaceutical ads.

Call for Graphic Designers

We’re on the search for some truly talented individuals. Check our posting for a chance to be part of the creative team here at Incase.

Modern Prefab

Forget every thing you know about prefab homes. This site is a great resource for information on the modern prefab movement.

Design Source

Dwell mag offers a design source for all your “dwell lifestyle” needs. Only covering NYC, SF and LA, for now.