The problem -
Thermoforming machines are the backbone of custom mouthguard manufacturing, particularly for high-impact sports like rugby and hockey, where you can expect a gnarly hit to the face. These machines rely on precise controllers to heat and mould plastic sheets into protective guards tailored to every individual’s teeth. But when our client’s decade-old control unit failed, production hit a wall!
With no existing schematics or drawings for this custom-built controller, they needed a partner who could reverse engineer the system efficiently and effectively. That’s where Winter & Smith came in.
Our smart solution
- Reverse engineering from scratch
We carefully deconstructed the controller, mapping out its functionality piece by piece to create a comprehensive circuit diagram.
- Optimisation and making it cheaper!
Replaced expensive, outdated components (e.g., a £60 part swapped for a £1.50 equivalent) while improving the overall reliability of the design.
- Streamlined design
Simplified the board layout to ensure better performance, easier troubleshooting, and a cleaner build.
Before:
Messy and broken, and very much in need of some modernisation.
After:
Clean, reliable and cheap. A board that will last many years to come.
Reverse engineering success
The redesigned controller exceeded expectations, offering a host of improvements over the outdated original. Not only was it significantly more cost-effective, thanks to thoughtful component replacements like swapping a £60 part for a £1.50 alternative, but it was also far more reliable. The new design eliminated previous outdated weaknesses, streamlining the layout for better performance and long-term durability.
We delivered 12 fully functional units, ensuring the client’s production line could operate seamlessly and meet ongoing demand. By optimising the controller, we provided a modern, scalable solution that bridged the gap between legacy equipment and current technological standards. And they’re still going strong!
Why reverse engineering matters.
For tech-driven industries relying on bespoke or outdated systems, reverse engineering is often the most practical path to innovation. It bridges the gap between legacy technology and modern performance, extending the life of critical machinery while introducing new efficiencies.
Winter & Smith specialises in turning technological roadblocks into opportunities. When your systems fail, we don’t just fix them—we make them better!
