Project Summary:
A provider of aftermarket locking solutions for pick-up truck tailgates utilized LJB to design a locking tailgate handle. The project scope included both a mechanical and power locking option. The replacement handle needed to look visually the same as the OEM provided handle but include a manual lock cylinder not currently offered as an OEM option.
Services Provided:
- 3D Scanning and Reverse Engineering
- Mechanism Design
- CAD Design and Drawings
- 3D Printing
- FEA Analysis
- Design for Manufacturing
- Vendor Management
- Fixture Design
- Testing
- Project Management
Project Challenges:
The design needed to fit in the current handle envelope and work with the complicated OEM latching mechanism as well as be able to accommodate a power add on in. The handle needed to duplicate the OEM handle a-surface with the addition of the lock. The handle and lock mechanism was required to meet a minimum of 30,000 life cycles. The handle material was also required to be paintable.
LJB’s Product Solution:
LJB acquired, scanned, and reverse engineered the OEM non-locking handle and added a mechanical lock to work with the OEM mechanism. Prototypes were built and evaluated on custom designed and fabricated test fixtures all completed with LJB’s internal capabilities. A detailed DFMEA and test plan were completed prior to releasing production tooling. LJB tested and evaluated production tooled components prior to production release.
