Case Studies

Racing Bike Hydration Pouch                                                                  

Production Specifications:

Design and manufacture an aerodynamic hydration pack used by bike racers. Specifications required included a water bottle with a splash free, FDA compliant cap, secure fit to a unique handlebar design and a GPS unit mount. Material specifications included DEHP free, potable water compatible bottle, UV stable covering, and recyled, retail-ready packaging.

Product Development:

Our Product Development Team created 3-D models of a blow molded water bottle, an injection molded GPS mount, and a molded silicone rubber cap. Our Asian Business Manager worked with our China sources to develop tooling and source compliant materials for required features of the water bottle.

Approved Hydration Pouch Assembly:

The outer cover material chosen was anti-skid, black neoprene in ball pattern. Silver neoprene and a zipper closure sewn with red binding was used to enhance styling. Shock cord straps were used to secure the silicone drinking tube and adjustable straps were used to secure the pouch onto the bike. Hang cards made of recyled chip board were used for retail packaging. All materials used were DEHP free and FDA compliant. Polo sourced all manufacturing processes and materials overseas.

Medical Leg Cuff Assembly

Production Specifications:

Manufacture a sewn leg cuff used to aid persons with drop-foot paralysis. All materials needed to be RoHS compliant and latex-free. The cuff needed to have a high quality appearance, be comfortable to wear, incorporate a custom injection molded armature assembly and latch, and strategically placed electrodes.

Product Development:

Our Product Development and Purchasing Teams worked with a domestic injection molder to manufacture the armature assembly, electrode liners, and latch assembly. Polo also worked with a domestic thermoformer to create a semi-rigid liner for the cufff.                                                                                                                                                 

Approved Design:

The outer cover and thermoformed liner material chosen was brushed tricot in cool gray color. The injection molded armature assembly gave rigidity to the cuff and allowed the wearer to easily put on and take off the cuff. Two injection molded square and round electrode locators were incorproated on the inside of the leg cuff according to the location of the wearer's common peroneal nerve. The leg cuff was supplied completely assembled for ready-use inside a zip lock bag and packaged in a custom printed carton that included an instruction sheet. Polo sourced and coordinated all manufacturing processes and materials used for this product.