Designing for assembly and serviceability
Services
- Design engineering
- Manufacturing support
- Performance testing
- Industrial Design
- Rapid prototyping
- Interface design
- Aesthetic refinement
- 3D modelling
- Aesthetic models
- Functional prototyping
- Concept generation
- User testing
Sector
- industrial
Client
Website
https://mikrofill.com/Mikrofill is a UK manufacturer of water pressurisation systems used in commercial heating and water infrastructure. These systems are typically installed in plant rooms and service environments, where reliability, ease of installation and maintainability are critical.
We were initially engaged to support industrial design concept development for a new ‘Pro’ version of the Mikrofill 3 pressurisation unit. As the programme evolved, our role expanded into mechanical design and engineering support through to production for the Mikrofill 3 Pro, alongside design input and appearance model creation for the Mikrofill Mini and Midi products for launch at a tradeshow.
The Mikrofill 3 Pro required a ground-up redesign of its mechanical architecture to improve assembly efficiency, serviceability and manufacturability.
The unit needed to be installed within the same space envelope as the previous product, while integrating a newly developed internal plumbing system designed by Stuart Turner’s engineers. This created significant packaging challenges, particularly around wiring, PCB access and component layout.
At the same time, the product needed to be easier to assemble on the production line, easier to maintain in the field, and more efficient to manufacture - all within a fixed timeline.
The Mikrofill 3 Pro needed to fit within the same physical envelope as the previous product to enable straightforward replacement in existing installations. This constraint remained fixed, despite significant changes to the internal system architecture.
The unit contained multiple PCBs, wiring systems and connections to building management systems. Routing and managing up to 16 wires, while maintaining accessibility and reliability, was a major challenge.
Enabling layered servicing without compromising sealing performance
The Mikrofill 3 Pro was designed around a multi-layer access strategy, allowing engineers to access different internal systems depending on the level of servicing required. Opening the outer front door provided access to key wetted components for routine maintenance, while a secondary internal access layer allowed deeper servicing of electronic systems and PCBs.
Developing this architecture created significant engineering challenges around hinge design, cable management and sealing. The system needed to maintain watertight integrity under pressure while still allowing smooth movement of the access panels and reliable access to internal components.
Designing for assembly and test
The design needed to support efficient assembly processes, including quality control and bench testing steps already established by Mikrofill. This required close alignment with real production workflows.
Components, including PCBs and wetted systems, needed to be accessible and replaceable without removing the unit from the wall, placing additional constraints on layout and access design.
We worked as an integrated extension of the Mikrofill team, providing additional engineering resource and specialist expertise in industrial design, prototyping and manufacturing.
Our approach focused on rapid iteration, early validation of key design features, and close collaboration with both the client team and manufacturing partners.
The programme was structured in phases, beginning with proof-of-concept prototypes and progressing through to detailed, production-ready design. This allowed key risks to be identified and addressed early.
We worked closely with Mikrofill’s internal teams and external suppliers, ensuring alignment between mechanical design, electronics integration and manufacturing processes.
Injection moulded, elastomer and sheet metal components were developed with a strong focus on manufacturability, including tolerance considerations, tooling input and assembly efficiency.
Extensive prototyping and testing
Prototyping was used throughout the programme, from small feature-level tests (such as hinges, seals and wire routing) through to full assemblies, enabling rapid iteration and validation.
A bespoke hinge and cable-management solution was developed to support the layered servicing architecture. This enabled multiple access stages within the product while maintaining sealing performance and durability.
Significant prototyping and iterative testing were carried out on the cable gland and sealing system to balance watertightness, manufacturability and freedom of movement within the hinged assemblies.
Multiple prototype iterations were produced and evaluated to refine the final solution, helping ensure reliable long-term performance while maintaining straightforward service access for engineers in the field.
Resolving real-world engineering challenges
Design decisions were informed by direct observation of assembly processes, allowing solutions to be developed that worked in practice, not just in CAD. This close collaboration helped identify practical assembly and servicing issues early, reducing rework later in development.
Alongside the 3 Pro engineering work, we developed industrial design concepts and high-quality appearance models for the Mini and Midi products to support range development and trade show launch.
The programme delivered a significantly improved mechanical design for the Mikrofill 3 Pro, supporting easier assembly, better serviceability and more efficient manufacturing.
Our work also supported the wider Mikrofill range through industrial design development and appearance models for the Mini and Midi products, helping establish a more consistent visual identity across the portfolio.
Improved assembly efficiency
The redesigned architecture reduced part count and simplified build processes, helping improve manufacturing efficiency.
Improved access to PCBs, wiring and internal components enabled easier maintenance and reduced service time in the field.
Detailed design development and supplier collaboration ensured components were suitable for production and aligned with manufacturing capabilities. This included close engagement with tooling and manufacturing partners to validate moulding strategies, tolerances and assembly approaches before release.
Reduced technical risk through prototyping
Early and ongoing prototyping helped validate key design decisions and reduce development risk.
Industrial design input and appearance models for the Mini and Midi supported wider product development and launch activities.
This project was about solving real engineering challenges within tight constraints. By working closely with the Mikrofill team and focusing on assembly, serviceability and manufacturability, we helped deliver a design that works both on the production line and in the field.
