Sheet metal, Medical
Touchless Soap Dispenser
Overview
We were tasked with developing a wall-mounted, touchless soap and hand sanitizer dispenser using Time of Flight (TOF) sensors as well as the client’s existing PCB technology. The design needed to function as a standalone product while also integrating into Z1.2 mobile handwash stations. We utilized brushed sheet metal for aesthetics and stainless steel for hygiene and durability. A primary challenge we faced in this project was space optimisation: The dispenser needed to hold the electronics, dosing pump, and liquid reservoir while still allowing easy refill. We also prepared the design for scalability so it could shift to plastic injection molding if production volumes increased.
Methodology
The design process began by defining the technical constraints around the PCB and dosing modules to make sure all components fit inside the internal chassis. We used stainless steel for durability and hygiene, with brushed sheet metal and acrylic front panels to match the company’s existing product range. Stamping and folding techniques were used for precision manufacturing, while flexibility was built into the design for future scalability with injection molding. Our biggest challenge was creating a space-efficient layout that kept the electronics separate from the liquid reservoir and batteries while still allowing easy maintenance. We also developed custom locking systems to prevent tampering and to ensure security.
Results Discussion
The touchless dispenser was initially designed for standalone use but faced challenges with battery-powered operation due to the high energy consumption of TOF sensors. Despite efforts to optimize power usage, it became clear that a large battery pack would be impractical. As a result, we adapted the product for integration into the Z1.2 mobile handwash station, allowing it to draw from a constant power source. The dispenser succeeded in meeting the client’s needs as part of the Z1.2 system, retaining its sleek design and functionality with the capacity for future mass production.
We were tasked with developing a wall-mounted, touchless soap and hand sanitizer dispenser using Time of Flight (TOF) sensors as well as the client’s existing PCB technology. The design needed to function as a standalone product while also integrating into Z1.2 mobile handwash stations. We utilized brushed sheet metal for aesthetics and stainless steel for hygiene and durability. A primary challenge we faced in this project was space optimisation: The dispenser needed to hold the electronics, dosing pump, and liquid reservoir while still allowing easy refill. We also prepared the design for scalability so it could shift to plastic injection molding if production volumes increased.
Methodology
The design process began by defining the technical constraints around the PCB and dosing modules to make sure all components fit inside the internal chassis. We used stainless steel for durability and hygiene, with brushed sheet metal and acrylic front panels to match the company’s existing product range. Stamping and folding techniques were used for precision manufacturing, while flexibility was built into the design for future scalability with injection molding. Our biggest challenge was creating a space-efficient layout that kept the electronics separate from the liquid reservoir and batteries while still allowing easy maintenance. We also developed custom locking systems to prevent tampering and to ensure security.
Results Discussion
The touchless dispenser was initially designed for standalone use but faced challenges with battery-powered operation due to the high energy consumption of TOF sensors. Despite efforts to optimize power usage, it became clear that a large battery pack would be impractical. As a result, we adapted the product for integration into the Z1.2 mobile handwash station, allowing it to draw from a constant power source. The dispenser succeeded in meeting the client’s needs as part of the Z1.2 system, retaining its sleek design and functionality with the capacity for future mass production.
Precision Sheet Metal Fabrication
Turned Parts Manufacturing
Electronic Housing & Management
Battery Integration
Engineering Plastics
Silk Screening & Print File Generation
Punching & Stamping
Specification Writing
RFA/BOM/SOP Implementation
Engineering Drawings
3D CAD Data & Wire Drawings
Turned Parts Manufacturing
Electronic Housing & Management
Battery Integration
Engineering Plastics
Silk Screening & Print File Generation
Punching & Stamping
Specification Writing
RFA/BOM/SOP Implementation
Engineering Drawings
3D CAD Data & Wire Drawings
"Our design balanced space constraints with functionality, resulting in a product that seamlessly integrated into a broader system while maintaining the company’s signature aesthetic."
