Radiation Detection, Built Rugged for the Field
Our Solution
How we helped a Leading Dosimeter brand develop a cutting edge radiation survey meter
The Result
A product that can be manufactured on demand using Additive manufacturing in the US with built in redundancies to handle supply chain fluctuations.
Setting the Context
Arrow Tech Inc. is a U.S.-based company specializing in radiation detection instruments. Their devices are carried into power plants, industrial sites, and along transit routes where radioactive cargo may pass. In these environments, reliability is non-negotiable. Survey meters, the class of devices Arrow Tech was developing, are handheld instruments used to detect and measure radiation levels in real time. They help inspectors pinpoint hazards, monitor exposure, and ensure compliance with safety regulations.
THE CHALLENGE
Ruggedness Under Tight Constraints
Arrow Tech needed a new survey meter designed for rugged field use. The device had to withstand drops, rain, dust, and rough handling while meeting Mil-Std-810H impact standards and IP67 ingress protection. At the same time, the project carried significant constraints:
- Their embedded electronics partner was based in the U.S., so the design process had to minimize iterations to control cost.
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- Production volumes would be modest, making injection moulding and expensive over-moulding techniques unjustifiable.
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- The product had to be manufactured in the U.S., aligning with government procurement incentives.
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In short, Arrow Tech needed a survey meter tough enough for nuclear inspectors and first responders, but economical enough to win competitive tenders.
THE SOLUTION
Designing for Ruggedness Without the Usual Tools
Impact protection is often achieved with dual-shot housings or over-moulded rubber. Cost constraints ruled both out. We had to design protection into the geometry and materials of the housing itself. Every curve, slope, and rib was engineered to absorb and distribute impact forces without the cushioning normally provided by elastomers.
Sealing the Battery Zone
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A removable battery is essential for field use but creates a vulnerability. We sealed the interface between the battery cover and housing with a continuous gasket and used captive fasteners to prevent screws from being lost in the field.
A Smarter Display Seal
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Instead of a gasket between the display and housing, we bonded a polycarbonate bezel with masked opening using IP68-rated adhesives. This was a technique borrowed from smartphone assembly. It cut costs, simplified assembly, and made display replacement straightforward at end of life.
Manufacturing Without Injection Moulding
Arrow Tech was clear: the product would be built in the U.S., at low volumes, and without investing in costly tooling. We designed the survey meter for additive manufacturing using DLP (Digital Light Processing).
Additive Manufacturing for Low Volumes
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- High surface quality and dimensional accuracy.
- Scalable to 100,000+ parts within days, proven by suppliers.
- Eliminates tooling costs while keeping production flexible and domestic.
Adding a Marketing Edge
In a category where many tenders are decided not just on performance but on perceived reliability, appearance matters. We developed a CMF palette that signaled durability and professionalism. To support Arrow Tech’s sales efforts, we created high-resolution CGI renders of the survey meter in multiple color options, giving them polished visuals for their website and bid documents.
THE RESULT
The final survey meter delivered on every front
- Ruggedness: Compliant with Mil-Std-810H, capable of taking real-world knocks without failure.
- Ingress Protection: Sealed to IP67, reliable in rain, dust, and mud.
- Manufacturing: Designed for additive production in the U.S., bypassing tooling costs while remaining scalable.
- Serviceability: Battery compartment and display designed for easy field maintenance.
- Marketing Readiness: Professional CMF and CGI assets that gave Arrow Tech an edge in competitive bids.
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Takeaway
Arrow Tech now had a product tough enough for the field, economical to produce, and credible to present in government tenders. A survey meter engineered not just for performance, but for the realities of cost, manufacturing, and marketing.
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Looking to design rugged, compliant products for new markets? Get in touch with us to make it happen.