Case studies
Cover for breathalyser

A global name in safety and protective equipment developed a compact breathalyser. The cover for this device needed to be formed, printed, abrasion resistant, robust and optically excellent. One production method that could deliver the desired result was injection moulding combined with printing/foil and coating. On the other hand, the startup cost for this type of product is high, which presented a problem given the annual volume was relatively limited.

We developed several prototypes based on the drawing provided. Using these, the customer was able to develop and refine its own prototype. As we don’t use expensive moulds, we are able to produce different versions during the design stage.

To manufacture the eventual design, Zweko coats flat sheets with a thermoformable abrasion-resistant coating, has the reverse side printed, machines the outline and forms the covers. Following a comprehensive final quality check, the products are cleaned and neatly packaged. Using these methods, we deliver production runs totalling several thousand items per order.