Nuts-and-bolts industrial design is giving form to objects that improve millions of people's lives. And rarely getting credit for it. In fact, most of the people whose lives are improved by this object don't even know it exists.

The internet in your homes or offices may reach you wirelessly, but it still gets to your building the old-fashioned way. Telecoms rely on cables, and cables rely on connections. When those connections fail, productivity is lost, repair techs are deployed, time is wasted, resources are spent.

Why do cable connections fail? Canadian technician Joshua Guimond studied the problem, and determined that improper installation of the connectors is a common culprit. If done right the first time it would eliminate the need for re-work, saving countless repair calls and dollars. Guimond zeroed in on the need to make the jacketing of the cables more pliable, particularly in colder climes. Introducing this pliability makes it easier for a technician to install the connector with rock-solid results, and with less effort.

What Guimond needed was a handheld device that a technician could use to quickly heat the cable tips during installation. To make this HeatPrep invention a reality, he needed an industrial design and engineering consultancy.

"Josh Guimond, founder of HeatPrep® came to Design 1st, looking for help to transform his vision for a handheld cable heating device into a manufacturable product ready for mass production," the firm writes.

Product Design Requirements

- Heat up cable in under 15 seconds

- Durable, with long-lasting battery for rugged, cold work environments

- Fit into existing tool pouches of telecom technicians

- Support multiple types of cable connections

Design and Engineering Challenges

Implementing Design 1st's proven process, the team was able to overcome several obstacles, including:

- Testing, and selection of the best conductive materials that insulate hand and heat multiple cable types

- Device testing to ensure proper function in extreme outdoor environments ranging from -30°C to +30°C

- Multiple rounds of bench model prototype testing to optimize battery, materials, heat, and cable connections

Bench Model Prototype for Testing

Pre-Production Prototype Parts for User Testing Trials

HeatPrep® Product Results

After a twelve-month product development journey, Josh Guimond traveled to China with the Design 1st team to oversee the first volume production run. Six months later, HeatPrep landed an exclusive licensing deal with the world's largest telecom cabling tool company, CablePrep®.

- Went from idea to prototype, to manufacturing and landing an exclusive licensing deal in sixteen months

- Positive reviews from telecom technicians across North America, saving 1000x costs on rework times due to faulty connections.

Says Guimond: "Design 1st's ability to identify and eliminate design risk and deliver an amazing user experience is now paying dividends as the sales grow. They helped us realize our vision, and provided a quality manufacturing solution, allowing us to concentrate on marketing and sales."

You can see more of Design 1st's work here.