Ascentcare came to Esox with a real challenge. They were looking to develop a series of complex silicone products. They had one size completed and were in a serious time crunch to develop three additional sizes, with precise variations to each size. We quickly recreated their original design and then worked closely with the client to develop the remaining sizes. We had to move very fast, especially considering the project’s complexity and the challenges we came across during development. We worked within very specific requirements, helped them expedite the project, and enabled our client to bring it to market even faster than they had hoped.

In the summer of 2020, a client came to us with an idea for processing Covid-19 batch samples using vacuum evaporation to reduce the sample size and increase viral particle concentration. We began by creating a simple test apparatus which quickly showed that the idea wouldn’t be so simple in execution. We had to overcome several barriers along the way by leveraging a sound knowledge of chemistry, thermodynamics and physics. With all the science applied, our team was able to come up with a novel concept combining different customized technologies to allow our client to scale up to larger production volumes. This project success story was even presented at the International Association for Food Protection 2021 Conference in Phoenix.

Our client couldn’t understand why a latch that was designed for them wasn’t working. After throwing some initial ideas around, we took on the project and let our engineers dig in. In a group meeting, one of our team members sketched out the problem on the whiteboard. We worked through some Free Body Diagram math and started to realize the design had serious flaws. Later we went through the results. The math showed that the load on that latch, combined with coefficients of friction and binding ratios, were causing the latch to bind. Our team went back to the client with a clear explanation of what wasn’t working, as well as design tradeoffs that could improve performance. We also gave them several viable alternate designs that could avoid the problem all together and work in the space they had.

Sounds simple enough, but as we better learned their process and needs we recognized there was a lot more involved. We discovered they were also looking for a way to measure the volume of materials as well as weigh it.

We began the process with product research, benchmarking, and digging into our client’s true needs. We then developed a full project scope. We not only aided in the product design and engineering, but in locally sourcing the large plastic injection molded parts. The concept development was a collaborative process with our client leading to a smart, functional solution that not only checked all the boxes – it eventually became an entire product line.

An existing client called us with an interesting challenge. They had a small plastic container that needed to be opened during their manufacturing process. Employees had been popping the lids off for over 20 years – but nobody liked the job and they were looking for a way to automate.

24 hours later, our team had already 3D printed several ideas and we were playing with parts and discussing solutions. At the end of the investigation phase, we had created two different machines powered by hand drills and our client tasked us to build a working prototype for evaluation. We sourced the necessary parts from common sources and designed and printed components. Two months later the “popper” is still opening containers and their team loves it!

We were asked to automate something in an industry typically devoid of automation – and that “something” was a 20 lb fixture that our client needed moved and positioned with no person involved. They also needed a prototype...fast!

Our team used the basics of an existing open-source arm and modified the idea to meet the range of motion needed. We found off-the-shelf stepper motors, a hobby grade controller, and wrote the code to drive the motors through Esox designed and 3D-printed belt drive systems. We went from request to functioning prototype in an incredibly short period of time while meeting or often exceeding all of the client’s design requests. Our customer was ecstatic, and we’re currently working on a second generation iteration of the design.