In its search for new handles, Holmatro came across Promatrix, a company that they had been outsourcing injection moulding work to for some time, but had never partnered with on a complex development process before. ‘When we started developing our new line of Pentheon rescue tools, we felt we had to take a novel approach to the handle.’

‘In the past, we used heavy steel handles’, says Rene van Eindhoven, Senior Research Engineer at Holmatro. He has been involved in the development of the new tool handles since the project started in 2017. ‘Later, we switched to aluminium brackets, which were prone to bending and damage when the tools got stuck. They were also quite expensive. All things considered, we decided we would design a new handle from the ground up.’

‘We were looking for a cheaper production technology, and while it didn’t take long for someone to suggest plastic injection moulding, not everyone was convinced right away. We make heavy-duty tools and the last thing we want is for a handle to break. It took quite some effort to get people to see plastic as a feasible solution.’

‘We turned to our development partner, who suggested gas-assisted injection moulding as a way to create a hollow, oblong plastic mould. It was exactly the solution we had been looking for. We saw lots of promise and ordered a pilot mould from Promatrix in the research phase. It wasn’t an obvious move, since moulds are not cheap, but because we already knew Promatrix, we felt comfortable taking the plunge. They make aluminium moulds, which are relatively affordable. We also really liked the fact that they make their own moulds in the Netherlands and could make quick and cost-effective tweaks where necessary, making them a good fit for the prototype phase we were in.’

‘With the mould, we could easily have an initial proof of concept injection moulded. The idea was to test GAIM with several materials, but the pilot tests we ran with the material suggested by Promatrix were an instant hit. We couldn’t break them, no matter how hard we tried. We could bounce the tools and handles on the ground and bend them quite considerably, and they would still return to their original state. The same happened in our lab tests, where we subjected each and every part of the handles to a hydraulic press, both at high temperatures (55°C) and low temperatures (-20°C). Finally, we conducted drop tests by throwing the tool several metres in the air and bouncing it on the ground. The tests were conclusive, and taking the next step was a no-brainer. It’s a cost-effective, ergonomic, scratch-resistant, visually appealing and durable solution.’

‘They don’t shy away from a challenge at Promatrix’

Injection moulding gives you much more design freedom than aluminium. The hollow, bendable nature of the material is a massive advantage. We also loved that the material does not develop any sharp edges when scratched and that the underlying material is the same colour. As a final touch, Promatrix also made it possible to incorporate six LED lights in the handle, which have to be wired to the battery. Because the handles are hollow, all the wiring could easily be concealed inside.’

‘Our design with three hollow spokes put Promatrix into uncharted waters. Without making any hard promises, they took up the challenge and the results speak for themselves. Their employees are open-minded, thoughtful and focus on the solution, not the problem. The whole process was as smooth as could be, and we’d happily collaborate on more products in the future.’