Air stack

Brief: Polyethylene Air Stack, with epoxy coated metal grille. The Air Stack is attached to a concertina rubber connector.


We worked with a manufacturer of refuse collection trucks who design vehicles to meet the changing needs of modern day refuse collection. Our brief was to produce a new Air Stack for their latest collection of vehicles.


We began by designing and building a full size timber model to ensure proper clearance on the vehicle cab. To help in developing the tooling, the model was produced 4% oversize and also used to create patterns for it.


A late but vital design change requested by the client threatened to delay the production of the units but we worked effectively to accommodate the change with no impact to deadlines and very little increase to cost.


The final mould was manufactured using a sand casting process and the product itself was produced using rotational moulding.