Project Overview
Autowbrake develops trailer-mounted brake control systems designed to improve safety and performance for towing applications. As demand for their product grew, their existing enclosure solution began to create limitations in both cost and functionality.
BeraTek partnered with Autowbrake to replace an off-the-shelf enclosure with a fully custom-designed solution, improving product performance while significantly reducing production costs.
The Challenge
Autowbrake was relying on a standard, off-the-shelf electronic enclosure that introduced several issues:
- High component cost impacting overall product margins
- Poor fit for the specific application
- Ineffective waterproofing
- Inefficient assembly process
These limitations not only increased costs but also created performance concerns in real-world conditions. The goal was to design a better enclosure tailored specifically to the product.
Our Approach
– Engineering Analysis & Redesign
BeraTek’s engineering team began by evaluating the existing enclosure and manufacturing process. This allowed us to identify where inefficiencies and performance issues were occurring.
From there, we developed a fully custom enclosure design focused on:
- Improving waterproof sealing
- Reducing unnecessary material and cost
- Simplifying the assembly process
- Enhancing overall product durability
The result was a design built specifically for the application rather than adapted from a generic solution.
– Design for Manufacturability
Once the new enclosure concept was finalized, our team optimized the design for efficient production.
This included:
- Refining geometry for injection molding
- Reducing part complexity where possible
- Ensuring consistent quality across production runs
These steps helped streamline production while maintaining high performance standards.
– Manufacturing Implementation
BeraTek transitioned the new enclosure into production, replacing the previous off-the-shelf component with a custom-manufactured solution.
The manufacturing process focused on:
- Consistent part production
- Tight tolerances for proper sealing
- Supporting efficient assembly integration
This allowed Autowbrake to improve both product performance and production efficiency at the same time.
The Results
The new custom enclosure delivered measurable improvements across the board:
- 75% reduction in enclosure cost
- Improved waterproofing and product reliability
- Faster, more efficient assembly process
- A cleaner, more refined product design
By replacing a generic component with a purpose-built solution, Autowbrake was able to enhance both product quality and profitability.
Client Feedback
“Our company has been working with BeraTek since 2015. It is challenging to find a company that will work with small businesses and offers competitive price points. BeraTek can work with any company, large or small with full turnkey or a la carte services including CAD design, prototyping, 3D printing, and manufacturing services in house. BeraTek provides extraordinary service.”
— Carlton Saunders, Owner – Kyle Group, LLC
Why This Project Matters
The Autowbrake project shows how custom engineering can unlock both cost savings and performance improvements. By rethinking a single component, BeraTek helped transform a critical part of the product into a competitive advantage.
This case highlights the value of moving beyond off-the-shelf solutions when product performance and efficiency are on the line.
Website – www.getautowbrake.com