Button Surround Replacements

 

Design | Reverse Engineering | Low Volume Manufacturing
Industry: Transport

The Challenge

Go-Ahead London identified recurring failures with the button surrounds on driver control panels, which were breaking over time due to repeated use. The supplier only supplied full button and surrounds assembly as a full unit, meaning this would be a costly replacement for our client. A more robust solution was required that could withstand repeated use while remaining compatible with the existing control panel layout.

 

The Solution

Where space allowed, the geometry was modified and reinforced, increasing wall thickness and strengthening previously weak features while maintaining compatibility with the surrounding components. The updated designs were manufactured using SLS 3D printing. Once printed, the parts were dyed black.

 

The Results

  • Improved durability of button surrounds in high-use areas.

  • Reduced breakages caused by repeated button presses.

  • Reinforced geometry without impacting fit or function.

  • Strong, production-ready parts produced using SLS.

  • Consistent black finish achieved through dyeing.

  • Lower maintenance requirements and extended component life.