Overview
‍At the start of this project, we took over a partially prototyped handwash tap that already had a registered design, but suffered from major structural and mechanical issues. Our challenge was to improve functionality without altering the original design. The existing prototype had poorly fitting parts, an overly heavy head, and sealing failures with O-rings. Electrical discharge machining caused minor leaks in the water channels, and the tap's dual PCB system posed both cost and quality concerns. To address these issues, we re-engineered both the mechanical and electrical components, sourcing bespoke parts and designing innovative solutions - all while keeping the original aesthetic. The goal was to create a versatile, standalone product suitable for various handwashing installations.

‍Methodology
‍Our approach began with addressing the prototype’s mechanical instability caused by poor tolerances and a heavy head. To reduce weight and maintain precision, we switched to a cost-effective boring process that also avoided leaks from electrical discharge machining. Collaborating with the electrical engineering team, we streamlined the original two-board PCB design into a single, more efficient board. We created custom jigs and rubber seals to protect the electronics, keeping them watertight and securely installed. We worked with external suppliers to source all components, created interface adapters for different installation setups, and produced precision-turned brass parts to complete the assembly.

‍Results Discussion
‍Our redesign improved the tap’s structural integrity while keeping the original registered form. Switching to a bored machining process eliminated leakage issues. By streamlining the PCB design, we were able to securely pot and seal the  electronics. We sourced and designed precision components specifically for this project, making the tap durable and compatible with a variety of installation setups. Despite initial challenges, our engineering solutions ensured the tap met all functional and aesthetic specifications, turning it into a manufacturable product.