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Tray design for Good Sleep Co's adjustable sleep device

A two-part tray for Good Sleep Co's adjustable sleep device, reverse engineered and designed in 3D over five revisions.

Client
Good Sleep Co
Scope
Design only
What it is
A two-part tray with inlays, for an adjustable sleep device
What we did
Reverse engineering and 3D design over five revisions
What the client got
The 3D files of each revision and of the final design
Start a prototype (opens WhatsApp) Send a brief
Revisions, from the first model to the final design
5
Pairings of upper and lower trays in the final set
6
Lateral relief tolerance, added in Revision 3
0.9 mm

What we brought

  1. What we can do

    Six settings from five trays

    Three lower trays and two upper trays pair up six ways, each setting the upper tray at a different offset, numbered 0 to 5.

  2. How we look after you

    Every part marked

    Each tray carries its code on the side, B1 and T1 at first and L1 to L3 and U1 and U2 in the final set, so the parts are easy to tell apart.

  3. What you get

    Small changes, one revision at a time

    The lower tray's tab came down from 11 to 10 mm, relief cuts went into the upper tray, and the upper tray grew 1 mm outwards so it is less likely to dislodge.

The build

How we built it

3 steps, from the brief to the finished piece. Pick a step to jump to it.

The brief

Step 1 of 3

Parts
An upper tray and a lower tray, each with an inlay
Our scope
Reverse engineering and 3D design for manufacture

At Additive Inn, our 3D printing studio in Singapore, we reverse engineered and designed a tray for Good Sleep Co's adjustable sleep device. The job was the design only: two trays that sit one inside the other, each with an inlay, delivered as 3D files.

Five revisions

Step 2 of 3

We modelled the tray as four parts: the top tray, the bottom tray and an inlay for each. Every revision went to Good Sleep Co as renders and a link to its 3D file.

  1. Revision 0

    The first model: a top tray and a bottom tray with a tall raised tab, a grey inlay in each and the part marks B1 and T1. In side view the bottom tray is 7.0 mm tall and 39.9 mm long.

    Render

  2. Revision 1

    A new tray shape with a lower, rounded tab, 11.0 mm high and square to the tray, and a stepped bottom inlay.

    Render

  3. Revision 2

    The tab came down to 10.0 mm.

    Render

  4. Revision 3

    Two lateral relief cuts in the inner curve of the top tray, with 0.9 mm of lateral relief tolerance. In side view the bottom tray is now 40.0 mm long.

    Render

  5. Revision 4

    The upper tray extended outwards by 1 mm so it is less likely to dislodge. The parts became a set: lower trays L1 to L3 and upper trays U1 and U2, which pair up in six positions numbered 0 to 5.

    Render

The final build

Step 3 of 3

Good Sleep Co received the 3D files of the final design: three lower trays and two upper trays, each with its inlay and marked with its code, which pair up in six positions.

RenderL3 with U2.

More product development

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