From idea to finished product – how we develop new van racking solutions

How does a new product from System Edström actually take shape? We talked to Daniel Borgudd, Product Manager, who tells us about the creative but also challenging work behind the scenes.

It all starts with a sketch. When it comes to the new products from this year’s launch, it is above all the new internal ladder holder that has kept Daniel Borgudd busy over the past year.

– Although we run individual projects, we are never alone. We need to be able to constantly question and give feedback to each other in the team, he says.

Daniel Borgudd joined System Edström in 2012, before which he worked as a naprapath, but after further training in Mechanical Engineering and CAD design, his career took a new direction.

– I did my master’s thesis here and that project is still something I can think back to sometimes,  he says, laughing.

From 3D printing to strength calculations

After the first sketches are produced, 3D prints are created to test and evaluate the ideas in practice.

– It’s one thing to see a product digitally, but quite another to hold it in your hand. We want to be sure that everything works before we move on to larger orders, explains Daniel.

The next step in the process is strength calculations – analyses that show how the product behaves under high loads.

Safety as a top priority

New products undergo rigorous testing, including crash tests, which are currently carried out at the Swedish National Road and Transport Research Institute (VTI) according to the safety standards INRS NS 286 and ECE R17. Previously, we also collaborated with RISE.

– We never compromise on safety. Our crash tests, and also the tensile tests we carry out, ensure that the products can withstand the stresses of reality. But just as important is that our assembly instructions are followed correctly, says Daniel.

Low weight for sustainability and cost efficiency

Keeping the weight of our products down is not only a question of price, but also of environmental impact. Lighter car interiors reduce vehicles’ fuel consumption and thus carbon dioxide emissions.

– Weight has a direct impact on both costs and the environment. The lighter our products are, the lower our fuel consumption and CO₂ emissions will be, says Daniel.

Continuous improvement – and close contact with users

Before concepts are approved, they are weighed against each other: function, appearance, weight and cost. When a concept is finally approved, a new phase begins and co-operation with suppliers intensifies. Prototypes are developed and testing begins.

But the work does not end there.

– We get a lot of feedback from our retailers, who in turn get feedback from end customers, and this can lead us to make small adjustments or even scrap an idea and start again.

He continues:

– Often it’s something as simple as adding a hole to make assembly easier, or customising mounting angles for a particular country’s needs.

Product development is an ongoing process, says Daniel:

– It’s challenging, sometimes frustrating – but above all incredibly fun!

The product development process looks like this, very simplified:

• Suggestions for a new product, can come from colleagues, customers or others.
• Market research.
• Concept development that can be in 2D & 3D, printed in plastic by us or made in steel from supplier.
• Testing, depending on the product, it can be FEM analysis, tensile test or crash test or a combination of all.
• Improvement if necessary.
• And so on to another department of ours, before the product is considered ready.

Curious to know more? Here you can find more info about our van interiors and our online configurator.