Overview.

A UK-based performance car manufacturer wanted to add an innovative, luxury feel to their latest model. Motherson was approached to design a lighting feature hidden within trim pieces along the door and glovebox fascia.

We introduced configurable lighting systems that allow vehicle occupants to adjust the color and intensity of ambient lights based on their personal needs – the latest in integrated comfort features from luxury car makers.

Trim pieces appear in a satin chrome finish, until lit, when ambient lighting appears in six colours, showing an intricate design. All features can be comfortably controlled by the driver.

Expertise.

Motherson is proud to be part of the new era of luxury automotive innovations due to our expertise in advanced surface coatings and the trust of our customers globally. As trusted partners, we’re able to work seamlessly with international car manufacturers, across time zones.

Our history within automotive means we have what it takes to build durable, high-quality products as expected by one of the world’s leading sports car makers. Using the latest SPEOS and Catia software, our design team applied lighting simulation and advanced coating technology to meet the brief.

Durability and visual quality of our metallic finish is achieved using the combination of controlled applications of liquid hardcoat with our custom, high-throughput, magnetron sputtering system. The deposit of multi-layer thin film coatings, creates the luxurious appearance of satin chrome.

Outcome.

The hidden-until-lit fascia and door finishers exceed the performance of electroplated chrome, are UV and abrasion resistant and will not yield to any common forms of corrosion, making them superior to any other comparable coatings.

We use optical-class, contaminantfree moulding processes to create high performance coated surfaces for complex components, all in our environmentally-controlled clean rooms.

The final product is shipped to the UK where it is part of the latest model build. We’re proud to be leading the way in ambient lighting for luxury brands and their customers’ enjoyment.

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Overview.

Orthopaedic surgeons required a device with a controlled delivery system to define and test suitable materials for promoting cartilage regrowth in knee surgery.

The 3dBioPen uses 3D printing methods enabling surgeons to draw live stem cells and growth factors directly on to the site of an injury. The shaft accepts 2 x standard syringes, one containing stem cell material and the other a hydrogel scaffolding material, extruded coaxially under an integrated UVcuring light.

This product has multiple extrusion speed options and helps surgeons design and personalise solutions for reconstructing bone and joint defects in real time.

Expertise.

Motherson was engaged by the University of Wollongong during the material development phase. Our end-to-end supply chain management meant we could support development of the delivery device from prototype tooling and component sourcing, through to final assembly.

With the customer brief in mind, Motherson applied expertise in mechanism design to develop the actuator, lighting design and simulation to perfect the UV-curing light and the effective development of electronic hardware and software.

We worked closely with the University of Melbourne and St Vincent’s Hospital as they began clinical trials and continue to support the research, development, design and manufacture of the 3dBioPen.

Outcome.

The 3dBioPen is a single-use, handheld device created in our stateof- the-art clean room to ISO 13485 standards.

Currently a prototype used in clinical trials by research groups within the University of Melbourne and St Vincent’s Hospital Melbourne, the 3dBioPen is manually assembled in a Motherson manufacturing cell as required.

We’re proud to be part of the solution, working with research in Australia to commercialise new medical devices.

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Overview.

With no structured rehabilitation program to accelerate recovery following knee reconstruction, prominent Adelaide Orthopaedic Surgeon, Dr. Matthew Liptak approached Motherson with a new concept.

The MaXm Skate is a fully integrated rehabilitation program designed to maximise function, reduce pain and improve outcomes following knee reconstruction surgery.

The patient’s foot is placed in the Skate, removing all load-bearing from the knee. Bluetooth sensors are connected to the knee and shin to track mobility during rehabilitation exercise. Data from the sensors is shared with the patient and clinician via the associated app.

Expertise.

Motherson worked with Dr. Liptak to understand his product requirements and delivered design for manufacture solutions combining volume manufacturing with user needs.

We supported product evolution using Catia software to design, analyse and manage the transformation. Prototype development included creating the mould, component sourcing, testing and evaluation. Motherson completed lab verification and achieved final assembly and packaging on time and within budget.

We’re proud to be part of our customers success and applied capabilities in Finite Element Analysis (FEA) to incorporate complicated geometries, loadings and materials to help make Dr. Liptak’s vision become a reality.

Outcome.

The MaXm Skate is a re-useable device that helps clinicians better manage patient recovery following knee reconstruction.

Currently a prototype used in clinical trials, the MaXm Skate is manually assembled in a Motherson manufacturing cell, with the ability to scale up when required.

Motherson provides value during clinical trials, continuing the design and manufacture process with customer needs in mind.

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Overview.

Current bladder cancer screening tests require an invasive cystoscopy. With the high recurrence rate of urothelial cancers and ongoing patient monitoring, cancer specialists were looking for a noninvasive test to alleviate patient discomfort and save time.

The Bladder Cancer Sensor is a ‘lab-on-a-chip’ diagnostic device for non-invasive, early detection of urothelial cancers. The test sends a urine sample through microfluidic channels, where antibodies are applied and selectively capture bladder cancer cells via plasma polymerisation and a microfluidics sensor. A stain and rinse is used to ensure the cancer cells can be easily identified under a microscope.

Expertise.

Motherson were proud to support knowledge transfer amongst the cross-functional team working on research and development for the Bladder Cancer Sensor. The team consisted of materials scientists, biologists, clinical researchers, urologists, manufacturing and design engineers.

Our collaboration with UniSA Researchers allowed us to translate the clinical opportunity from benchtop to patient.

Our products are built keeping patient safety and customer requirements in mind. Motherson embedded engineers in University labs and set up a pilot manufacturing facility capable of high-precision injection moulding and plasma polymerisation.

We created a functionalised surface using an ultra-thin plasma polymer, ready for the bladder cancer specific antibody and patient sample to be applied, bond and begin the selective capture of cancer cells.

Outcome.

The Bladder Cancer Sensor is a single-use device created in our state-of-the-art clean room to ISO 13485 standards. The final product is assembled manually, vacuum packed in a moisture and light (medical grade) proof bag including a desiccant for advanced moisture protection and sent to clinical trial teams.

Motherson is proud to be part of medical device innovation and together with UniSA’s Future Industries Institute and Flinders Medical Centre, the successful clinical trials of this CRC-P project continue.

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Overview.

A clinical team studying sleep for more than 25 years saw a gap in the market for a consumer product to assist people prepare for and recover from changes in sleep patterns.

The Re-Timer uses a peak wavelength of light in the greenblue spectrum to alter the circadian clock. When worn for approximately 60 minutes at specific times of the day, the Re-Timer will significantly suppress melatonin, allowing the user to shift their sleep rhythms.

Expertise.

Professor Leon Lack approached Motherson to be their full-service partner including product design, validation and assembly.

Motherson created CAD models and simulations using the latest Catia software and completed structural analysis and hazard assessments to achieve regulatory certification.

Keeping the customer at the forefront of our focus, Motherson applied expertise in mechanical engineering, quality engineering and optic and lighting technology, as well as end-to-end supply chain management.

This product is manually assembled in Adelaide using lean manufacturing processes, before being shipped to Re-Timer for worldwide distribution.

Outcome.

The Re-Timer is an ergonomic wearable device created in our state-of-the-art clean room to ISO 13485 standards.

Customers such as shift-workers, regular travelers and people affected by Seasonal Affective Disorder (SAD) can purchase the product directly from Re-Timer and receive the final product in a purpose-built, zip up case.

Motherson continues the full supply chain management for Re-Timer, from component purchase and assembly to traceability and logistics.

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Overview.

The world is no longer limited by location and scale when it comes to accessing data thanks to the Myriota Module. 90% of the earth’s surface has no Internet of Things (IoT) connectivity. Current technology is expensive, can’t scale and battery life is short.

The Myriota Module is a disruptively low cost way to securely retrieve data from anywhere on earth (land or sea). Using a robust design of onboard storage and a microcontroller for data pre-processing and compression, short messages ensure the product is cost effective and power saving. The direct-toorbit satellite network means users can count on coverage without having to plan, deploy or maintain a network.

Expertise.

Myriota undertook a global search for a manufacturing partner that would be able to support it’s business as it scaled and Motherson was successful in securing the contract due to our experience in high volume and high speed electronics manufacturing.

Motherson worked closely with Myriota to translate their research into a product that could be made at scale. Our automotive capabilities to make durable products for harsh environments were applied to the Myriota Module, along with tolerance understanding, testing, traceability, packaging and logistics.

We’re proud to be part of the solution for our customers and developed unique fixtures and processes, underlying the validation and product verification to ensure this product met strict IPC-A-610F class 2 manufacturing standards.

Outcome.

The Myriota Module is about the size of a piece of gum and has a range of applications benefiting industries including agriculture, transport and logistics, maritime, defence, environment, mining and utilities.

Assembly is fast and accurate using the latest Surface Mount Technology (SMT) lines including high speed and high volume pick and place machines, helping our customers reach their end user quickly.

The combined expertise from both Motherson and Myriota ensured a smooth transition into full production, driving great outcomes for Myriota customers.

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Overview.

The Reposit smart controller is an award winning, quick and easy addon for your existing solar battery. To make the most of your solar energy, this smart controller learns the energy patterns within your home to lower power bills and stores excess energy produced during the day, enabling access to solar energy at night.

Reposit harnesses the power of distributed energy by selling power back to the grid when the prices are highest, and is Virtual Power Plant (VPP) ready.

The Reposit smart controller system works in conjunction with an app that shows real time and predicted household usage, energy costs, solar generation and battery charge, along with insights into further reducing energy bills.

Expertise.

Motherson was engaged by Reposit to bring their product to life. By adding our own expertise in design for manufacture, we were able to unlock the full product potential through minor design tweaks.

The combination of economies from global component purchasing and lean manufacturing processes, meant we were able to provide cost efficiencies to meet customer expectations.

The quality core module hardware is produced on our Surface Mount Technology (SMT) lines on lead-free Printed Circuit Boards (PCB). Each PCB is run through our auto-optical inspection and undergoes a final test to meet ISO 9001 quality standards.

We’re proud to be part of the solution for our customers, providing a complete service from prototype production to full scale manufacture.

Outcome.

The Reposit smart controller is the first step into smart home automation with IFTTT (if this, then that) integration. Thorough testing and quality management ensures the final, branded product is received by our customer on time and within budget.

Motherson continues to manage the supply chain for Reposit, from component purchase and assembly to traceability and logistics.

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