Automated Speaker Grille Assembly & Heat Staking Machine
Mechanical CAD Design Services
Case Study
Automated Speaker Grille Assembly & Heat Staking Machine
Development of a multi-stage automated cell for precision tab folding and perimeter heat sealing.
We use the latest software such as Autodesk, Solidworks and many others.
The Problem
A customer required an automated solution for a delicate two-stage assembly process. The task involved folding mechanical tabs on a speaker grille once seated in its housing, followed by a precision heat staking operation to apply a perimeter seal. The manual alternative was too slow and lacked the consistency required for high-quality acoustic components.
Concept & Planning
Nova Design conceptualised a bespoke machine featuring a robust aluminum frame construction. The design integrated a pneumatic press head for the mechanical tab folding and a specialised heating element for the staking process. To ensure operator safety without sacrificing workflow, the unit was designed as a guarded cabinet with a clear polycarbonate front for total process visibility.
The Solution
Using advanced 3D modeling, Nova synchronised the mechanical folding and thermal sealing cycles into a single cohesive unit. We produced a comprehensive suite of detailed manufacture drawings for both the heat stake and tab folding assemblies. This precision documentation allowed for the successful fabrication of a machine that provides repeatable, high-quality finishes for every speaker unit.
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