Enabling Safe and Reliable Field Charging
Our Solution
How we helped a Leading Dosimeter brand develop a cutting edge dosimeter charger
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.
About Arrow-Tech
Arrow-Tech is a leading manufacturer of radiation detection and monitoring equipment trusted by defense, nuclear, and industrial sectors. Their products are known for reliability in the field and compliance with stringent global standards. Our partnership with Arrow-Tech has focused on translating this reliability into rugged, field-ready hardware solutions.
What are Dosimeters
Direct Reading Dosimeters are compact, pen-shaped devices that measure cumulative radiation exposure. They are widely used by military personnel, first responders, and workers in radiation-sensitive environments. Simple to carry and easy to read, these devices provide immediate feedback on radiation levels, allowing users to take protective actions in real time. A dosimeter’s effectiveness depends on being charged and ready for use, which is where the charger becomes critical.
THE CHALLENGE
Reliable Charging Under Extreme Conditions
Arrow-Tech required a dosimeter charger that would:
- Operate reliably in harsh field conditions, including rain, mud, and extreme temperatures.
- Support both daytime and night-time use.
- Remain compact, rugged, and intuitive.
- Pass Mil-Std-810H impact testing and IP67 waterproofing standards.
Be manufactured in a cost-efficient way within the United States to support government procurement initiatives and reduce inventory risk.
THE SOLUTION
Designed for Field Reality
We developed a rugged, field-ready charger designed for both performance and manufacturability.
Charging Well and Potentiometer
The dosimeter docks into a recessed charging well, where a potentiometer is used to set the required current. To protect this sensitive area, we designed a cap with an integrated retainer. The cap was potted at the bottom to ensure that rainwater or mud would not enter, even if left open during a storm.
Night-Time Usability
We integrated an LED flashlight for night operation. A three-position knob located between the potentiometer and the charging well controls the flashlight, switches it off, or activates a battery status display.
Battery Status Display
Four light guides connected to LEDs indicate the remaining power in the charger’s internal battery. This provided a clear and durable status system without requiring a digital display that could fail in the field.
USB-C Charging Port
To keep costs under control, we selected a consumer-grade USB-C port. We added a cap with retainer and gasketing to ensure ingress protection. Even during charging, the seal prevented liquid entry. A dedicated LED and light guide confirmed secure connection and charging status.
Ruggedization
The unit was designed to meet Mil-Std-810H for impact and IP67 for waterproofing. A removable battery cover, consistent with other Arrow-Tech devices, made servicing simple while maintaining ruggedness.
Why Additive Manufacturing Mattered
Producing the charger in low volumes made traditional injection molding prohibitively expensive due to tooling costs. By designing the enclosure specifically for additive manufacturing, with emphasis on DLP technology, we achieved several advantages:
- No tooling investment – freed Arrow-Tech from upfront costs associated with injection mold tooling.
- High finish quality – DLP enabled fine surface detail suitable for customer-facing equipment.
- Ruggedness with ergonomics – allowed us to integrate structural strength with user-friendly form factors.
- On-demand production – supported US-based manufacturing aligned with government procurement initiatives.
- Lean inventory – eliminated the need for large stockpiles, reducing overhead and enabling faster response to orders.
This manufacturing strategy allowed Arrow-Tech to keep aesthetics, ergonomics, and durability in focus while staying agile in production.
THE RESULT
Reliable Power Anywhere
The dosimeter charger enables Arrow-Tech’s customers to recharge equipment anywhere, at any time, under the toughest conditions. From rain-soaked field operations to low-light environments, the design minimizes user error and ensures reliable performance.
By pairing rugged field design with additive manufacturing, the solution aligned perfectly with Arrow-Tech’s long-term goals: to maintain compliance with government requirements, reduce inventory overhead, and strengthen the supply chain through on-demand US production.
The CGI visuals we created further amplified Arrow-Tech’s sales efforts, providing a clear, high-quality view of the product in use. Together, these elements allowed Arrow-Tech to reinforce its position as a trusted partner for radiation detection and monitoring solutions.
Takeaway
Arrow Tech now had a product tough enough for the field, economical to produce, and credible to present in government tenders. A dosimeter charger engineered not just for performance, but for the realities of cost, manufacturing, and marketing.
Looking to design rugged, compliant products for new markets? Get in touch with us to make it happen.