Project Summary

Client: McMurdo Marine

Product: Bridge mounted navigation equipment

Services: Product Design, Material Selection, Prototyping, Precision Machining, Injection Moulding, Production Tooling, Quality Control

Requirement:
Develop customised casings capable of protecting sensitive navigation electronics from saltwater, UV exposure and repeated temperature changes, while supporting practical installation and consistent manufacture.

Outcome: Durable, purpose-designed casings with improved sealing, handling and installation features, validated for demanding marine environments and developed into a repeatable production solution for ongoing supply.

Project Benefits:

  • Improved protection from saltwater ingress and UV exposure.
  • Improved handling and installation through refined grip and mounting features.
  • Reduced risk of equipment failure, field repairs and vessel downtime.

Background:

McMurdo Marine develops navigation and safety equipment for the maritime sector. Its bridge-mounted systems are installed on a range of vessels and must remain dependable throughout long periods of operation at sea.

The casing was therefore an integral part of the equipment rather than simply a cosmetic enclosure. Its design affected how the unit was mounted, how operators handled it, how accurately the internal components were located and how effectively the electronics were isolated from the surrounding environment.

McMurdo approached DTI for a customised solution that could bring these requirements together in one production-ready design. The project needed to move beyond an initial enclosure concept and establish a casing that could be tested, tooled and supplied reliably over the longer term.

Requirement:

The engineering challenge was to accommodate several competing demands within the same casing. It had to tolerate prolonged saltwater exposure, UV radiation and thermal swings of up to 70°C without losing dimensional stability or compromising the sealed interfaces.

The geometry also had to locate and secure the internal electronics accurately, provide suitable mounting points for different vessel installations and include grips that operators could use comfortably. Critical dimensions around the gasket and mating faces needed to remain consistent from prototype through to production; variation in these areas could affect sealing performance even when the casing appeared to fit correctly.

The solution also needed to:

  • Resist degradation caused by saltwater and UV exposure.
  • Remain dimensionally stable during repeated temperature changes.
  • Maintain controlled and repeatable sealing around the internal electronics.
  • Be practical to handle and install across different vessel types.
  • Support consistent manufacture and long-term product supply.

Solution 

Working with McMurdo’s engineering team, DTI developed the enclosure, seal, mounting points and grips as an integrated assembly. Resolving these elements together avoided the compromises involved in adapting an off-the-shelf housing and gave McMurdo a casing designed around the equipment itself, its installation and the people handling it.

DTI selected engineering plastics with the impact strength, UV resistance and thermal stability needed for the application. Considering material behaviour alongside the tolerances at the mating faces reduced the likelihood of distortion affecting the fit or seal during the casing’s service life.

Components containing the tight tolerances and critical sealing features were machined from solid material, allowing accuracy to be maintained where variation could affect water resistance. The grips were injection moulded to give operators a durable and comfortable handling point while providing McMurdo with a component that could be reproduced efficiently for future orders.

Double-lip gaskets and controlled compression channels were incorporated into the design. By controlling how far the gasket compressed during assembly, DTI reduced the variation between units and gave McMurdo greater confidence that the seal proven during development could be maintained in production.

Initial casings were produced in small batches so McMurdo could assess fit, installation and handling before committing to production tooling. Feedback from these trials informed changes to the seal, grip position and mounting features. This allowed practical issues to be corrected while changes were still relatively straightforward, reducing the risk of expensive tooling modifications later.

The prototypes then underwent mechanical and environmental assessment, including accelerated UV exposure, salt spray simulation and repeated thermal cycling. Testing gave McMurdo evidence that the assembled casing performed as intended under representative conditions and provided a stronger basis for approving the move into production.

Once the design had been validated, DTI established the tooling, manufacturing process and quality controls needed for ongoing supply. Dimensional, seal-compression and impact-resistance checks ensured that the functional details approved during development were carried through into production, reducing the burden on McMurdo to identify variation after components had been delivered.

Outcome:

McMurdo was able to bring its bridge-mounted navigation equipment into production with a casing designed around the realities of long-term marine use. The finished units combined secure housing of the electronics with the durability, water resistance and dimensional stability needed for installation on working vessels.

For McMurdo’s customers, the casing provided dependable protection for the internal electronics and easier handling during installation and use. Maintaining the integrity of the enclosure through saltwater exposure, UV radiation and changing temperatures helped reduce the likelihood of water ingress, avoidable equipment failures and disruption on board.

Consistency across repeat orders also meant McMurdo could rely on the same fit, sealing performance and component interfaces as production continued. This supported smoother assembly, reduced the risk of variation reaching the field and helped limit the need for casing-related repairs or replacement.

The established supply solution enabled McMurdo to support the equipment beyond its initial launch without repeatedly revisiting the casing design or sourcing a new production route. Continued repeat orders provided the reliable component availability needed to maintain the product throughout its commercial life.

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