Stanley and the DynaGrip Pro

When Stanley tools decided to reinforce their market leading position, re: screwdrivers, by introducing a new “state of the art” product range. Their objective was to achieve new levels of performance in the areas of torque and impact resistance, whilst at the same time, delivering a highly aesthetic and use friendly design. The new product would build upon their highly successful Magnum range, which itself had broken technological barriers some years earlier by featuring two shot “soft touch” technology. However, the yet unnamed programme would have to go much further than two shot technology, so as to achieve the torque and impact performance being demanded. The handle would need to be directly moulded on to the screwdriver bar. Other leading features such as tip symbol identification and colour differentiation were also fundamental to their plans.

Having considered the ‘step change’ nature of the technology required, Stanley concluded that they needed a class leading partner, if:

1. The sever technological challenges were to be over come and
2. The programme would be ready for a March 2000 launch at the Cologne fair.

After consulting with various companies around the world and a critical analysis of their capabilities, Stanley chose Burnett Polymer Engineering as its partner on the newly named Dyno Grip Pro range of screwdrivers. The programme would not only feature ground breaking technology, but for the first time, Stanley had decided to market the one product design in all of its major markets around the world – a sign of their confidence in the programme.

Having received the basic design and performance parameters from Stanley, Burnett’s set to work on developing a working design and just as important a manufacturing process to produce the screwdriver at the target price. Using the full resources available to a McKechnie group company, a considerable amount of modelling, mould flow and FEA analysis was undertaken, as we wanted to design a ‘core’ that would deliver the cycle and performance criteria necessary to underpin the product’s success.

Given the groundbreaking nature of Dyno Grip Pro, it quickly became clear that a radical method of manufacturing would also be required. Further, to reduce the risk to both partners, it was felt any production investment would need to be flexible and not limited to just the manufacturing of screwdrivers.

To achieve this goal we invited tender submissions from various machine companies, but in the end, Burnett’s unanimously chose Engel as its moulding and robotics partner for the project. Over the next 9 months, the respective teams from Burnett and Engel – Austria, worked hand in hand to refine both the product design and manufacturing process in the line with the key objectives laid down by Stanley.

The culmination of this work was the presentation of initial samples in March 2000 of moulded on bar screwdrivers that featured 4 shot technology to achieve the 4 colours required. Under test conditions, not only did the product meet all of the original torque and impact targets, but also the manufacturing output and QA objectives were achieved via the use of two fully automated production cells. This technological ‘tour de force’ is now distributed by Stanley to countries across the world, including UK, Europe and North America, underpinning Stanley’s desire to be “best in class” with their chosen market.