Balancing the Needs of EV Users & Manufacturers
Identifying the Need for a Redesign
Beyond Design was tasked by Harting with redesigning and prototyping a new EV Charging Connector that utilizes DAE J1772 technology. Market research showed that the current charging connectors felt uncomfortable and bulky, so the Client needed a more user-friendly and contemporary design to capture US market share. The goal of the redesign was also to maintain or lower production costs and part complexity to increase profits.
Connecting Research and Development
Beyond Design analyzed the form and functionality of Harting’s current products and competitors to think of improvements. Sketches and ergonomic studies were explored to assess how the product should look and feel. Our CAD engineers then designed and 3D-printed models in-house for validation. Physical prototypes, which we tested on different hand sizes, confirmed the redesign was balanced and comfortable while optimizing material efficiency.
After the design was refined, the mechanical assembly methods were evaluated and improved to make the product look more sleek and modern. This was achieved by concealing fasteners and screws in inconspicuous locations and by using Colors, Finishes, Materials, and Graphics (CFMG) to create a premium design aesthetic.
The Electrifying Results
Beyond Design’s attention to detail and rapid product development cycle created a Charging Connector that excels in form, function, and manufacturability. The final concept is comfortable, enduring, and contemporary, without driving additional costs. Beyond Design’s design process bridged the gap between EV consumers and Harting’s manufacturing needs.