BriskHeat’s ACR3 hot bonder has been a trusted resource for over 15 years across various industries that utilize composite materials. Common composite repair, manufacturing, and testing occurrences may be required for aircraft wings, high-performance cars, ship hulls, wind turbines, and various infrastructures such as bridges. As expected from these industries and applications, a portable hot bonder system controls heat and vacuum during processes that demand precision, reliability, and ease of use in the field. With the goal of building the next generation of the well-known ACR3, a project Design Central helped BriskHeat develop, their team engaged Design Central once again to help them elevate the user interface and ensure that every element of the design integrated seamlessly with the device’s complex internal configuration.
To explore the optimal interface layout for technicians, our team moved directly to foamcore models. These mockups, equipped with velcro components, allowed us to quickly move pieces around, test different layouts, and interact with the design tangibly. Bringing these models in front of the BriskHeat team gave everyone the chance to discuss first impressions of the ergonomics and connector placement rather than imagining how a design might feel from a screen. This approach produced a more intuitive architecture, including angled connectors for improved access, strategically positioned labels for user guidance, and a larger screen with an enhanced viewing angle, all while maintaining the device’s original footprint.
Improving the user interface of the hot bonder meant more than adjusting what was visible on the outside. Each external detail needed to coordinate with internal systems to ensure the device functioned effectively. Our team began strategizing how to enhance the organization of the ACR3’s dual zone operation, the ability to run the same cure on multiple zones simultaneously. The solution included relocating cable exits to the sides of the case to prevent hoses and wires from obstructing the work area, reorganizing internal storage for improved accessibility, and adding removable thermocouple boxes that can be positioned closer to the repair site for more precise monitoring. At the same time, our component routing was carefully planned to help the ACR4 survive shock and vibration during transport, while also maintaining airflow and ensuring mirrored manifold systems remained intact. The result was a user interface that enhances ergonomics and efficiency while remaining tightly aligned with the configuration demands within.
Following refinement of the design, two functional prototypes were constructed using 3D-printed thermocouples and CNC-fabricated sheet metal. These prototypes enabled BriskHeat to validate usability and performance prior to production. The design was adapted to fit BriskHeat’s newly sourced Nanuk case, providing a more durable and mobile housing with a removable lid, thereby increasing compatibility with various worksite configurations. In addition to case functionality, branding opportunities and strategic label placement were incorporated to reinforce BriskHeat’s identity in operational settings. The integration of user interface design with engineering precision resulted in the ACR4, a durable, intuitive, and reliable solution for critical composite repair environments.