TOOLS MULE

CaliberX & Branding

From its initial concept to the final product, CaliberX — an innovative multi-tool — demonstrated remarkable breakthrough potential within its niche market. The original request was refreshingly straightforward: create a new multi-tool, initially comprising a minimum set of specific tools, with the flexibility to incorporate additional features based on market insights.

Every step of its journey, from comprehensive research to precise technical drawings, was meticulously executed by the Fact & Form team. In February 2022, this visionary project successfully transitioned into the mass-manufacturing phase, thanks in large part to the unwavering support of over 775 enthusiastic crowd-funding backers. This remarkable achievement resulted in an impressive funding total of over $85,000.

Overview

client

TOOLS MULE

country

ROMANIA

timeframe

6 Months

type

Industrial Design / Tools

year

2019

Revolutionizing the Multi-Tool: A Journey of Innovation & Market Insight

Multi-tool design had stagnated for years, dominated by brands like Leatherman and Gerber, who mainly updated appearances. Competitors struggled due to quality and design issues. Creating a disruptive multi-tool demanded intricate design for niche consumers.

We collaboratively analyzed leading brands’ multi-tools and prioritized customer satisfaction. While crafting a perfect multi-tool for every market aspect is challenging, our approach focused on precise essential tools, material selection, and construction techniques to fulfill our product’s promise.

Brief

In the realm of multi-tool design, innovation had stagnated for years, with industry leaders like Leatherman and Gerber primarily focused on cosmetic updates to existing models. Meanwhile, other competitors struggled to gain traction, hampered by quality and design shortcomings that prevented them from challenging the dominant brands. Creating a multi-tool poised to disrupt this market required intricate design to meet the exacting demands of niche consumers.

Market research became the cornerstone of this project. A collaborative effort ensued after an initial client meeting, leading to an in-depth analysis of leading brands’ multi-tools. Furthermore, understanding customer needs was paramount, as prioritizing potential users’ satisfaction was paramount to the product’s success. While designing a multi-tool that perfectly aligns with every market nuance is a lofty goal, our approach focused on crafting a precise set of essential tools using the right materials and construction techniques to fulfill the product’s promise.

1.1.

Research & Discovery

  • Problem Comprehending
  • User Research
  • Market Analysis
  • Materials and Tech R&A

Alongside the process of vigorous research, sketches of multi-tool sub-assembly parts were constantly drawn to grasp a better understanding of their design. Being a vital step in the product’s conception, the characteristics of each tool were taken into consideration. The blade — an essential tool to be found in most multi-tools — could be designed and manufactured in countless ways; it could be thin, short, flexible, weak to rust, easy to break, shaped for cutting, shaped for stabbing, and so on. With that statement, every possible detail of sub-assembly parts was thought of alongside their fusion to a single multi-tool unit.

This process took over a month, frequently leveraging different ideas which would sometimes lead to completely rethinking the design of the tools or, in certain cases, completely removing the inclusion of a tool. Furthermore, production costs were directly proportionate to the type of material used, the manufacturing methodologies, and the complexity of final assembly. All were thought of to not impede the client’s specified limit for production costs, yet the actual amount was not finalized until after the prototype phase.

2.1.

Design Development

  • Detailed Design
  • Prototyping and Testing
  • Materials and Manufacturing Considerations

3D C.A.D. Modeling

Once initial sketches and the tool list were agreed upon, the journey towards creating the 3D CAD model commenced. We embarked on this path with unwavering precision, operating at an astounding level of accuracy. Each sub-assembly part underwent a meticulous draft drawing process.

At the heart of our design lay an ergonomic handle, carefully crafted to seamlessly accommodate the rest of the tools. We performed a thorough study of the human hand, while also factoring in the dimensions of the tools to be housed within. The result offered a comfortable grip and established the exact dimensions required for the tools.

The process wasn’t without its challenges, though. Some tools initially fell short of our determined standards. To ensure they met the mark, we had to reshape each tool — a process that occasionally disrupted the harmony of neighboring tools. The entire construction process spanned over the course of a month, as we meticulously honed our design to perfection, inching closer to the completion of the prototype-ready model.

Once the model was finalized and accepted by the client, the prototyping process began. The first prototype was 3D printed with ABS plastic and was used to verify the assembly, overall shape and ergonomics, and aesthetics of the product. Once the verification process was completed, a metal prototype was necessary (using 420 HC stainless steel, with a black oxide application).

Its creation was supported due to the collaboration with Hubs — a global prototyping brand — creating an accurate prototype that enabled the further analysis of any issues with the product.

The Final Prototype

Once assembled, the product was highly satisfactory in matters of design, apart from a few tools which could not reach manufacturing qualities (such as the rigidity and hardness of the blade and saw). After analysis, the adjustments of the 3D CAD model tools were completed, reaching another prototype phase. Two more prototypes were made, answering a set of concerns, until the fifth and final prototype was production-ready.

3.1.

Production & Implementation

  • Final Design Approval
  • Documentation
  • Manufacturing and Quality Control
  • Launch and Post-launch Activities

Upon analysis completion of the final prototype, technical drawings were made, in less than a month. 22 different sub-assembly parts were produced in accordance with ISO 128 standards. These included all tolerances (linear, angular, and surface), sections, notes, dimensions and measurements, surface finish, material, and production process requests.