HELPBOX 365

The initial scope of requirements focused on aesthetics and fitting three components - an AED, a first-aid kit, and an additional device, along with an onboard computer - which reflected the early visualization stage of the project. As the visualization began to take shape as a real product, we worked with the client to refine the full functional specification: a universal, networked station designed for use both indoors and outdoors, in public spaces and workplaces.

For this project, we departed from our usual approach of preparing 3-4 design concepts - we created only one version, which the client approved quickly, thanks to its strong visual quality. The key design idea was a transparent front (glass panel) that allows the cabinet's contents to be identified immediately - on one hand, this is a practical requirement (the user must know what's inside before opening the cabinet); on the other, it's a deliberate design choice aimed at building public awareness of defibrillators' presence in public spaces. To enable the fastest possible access to the cabinet's contents, instead of locks or breakable glass, we designed a tear-off seal and handle - eliminating the need to damage the front glass.

In addition to the front panel itself, another challenge was designing the shape of the entire enclosure. The cabinet shape we proposed in the visual concept ruled out the cost-effective use of bent and welded sheet metal for small production runs - the metal stamping dies would be too expensive, and welding would be too time-consuming and inconsistent.

During the material analysis phase, we decided to use expanded polypropylene (EPP) for the interior of the housing and thermoformed ABS for the exterior - a technology previously unknown in this type of product, which best met the project’s needs. We originally planned to make the front panel out of plexiglass (PMMA), but this material warped and did not provide the required flatness, which made effective sealing impossible - we replaced it with tempered glass, which is also more weather-resistant and less prone to scratching. This change, however, had a side effect: glass has much higher thermal conductivity than plexiglass, which required a redesign of the heating system (a larger heater, different component layout). We had a great deal of freedom in terms of aesthetics, but when it came to choosing the technology and production methods, we consulted with the client on an ongoing basis, working together to find the best solutions.

The mechanical components went through 3 to 5 iterations - the EPP molded part required the most changes (about 5 versions, the last three of which were purely cosmetic), and we collaborated with a specialized manufacturer of molded parts to refine it. The main design challenge was joining the EPP to the ABS housing, which required selecting the right adhesive. Another challenge was selecting the gasket: the original sealing design didn't work, and since the production tooling for these parts was already finalized, our options for redesign were very limited - nevertheless, after a series of tests, we managed to achieve a repeatable, watertight design.

The manufacturer suggested thickening the EPP walls, which we accepted without reservation, as it did not significantly affect the product but made production much easier. A greater challenge was the mismatch in demolding angles between the EPP and the thermoforming mold - we made a conscious decision to deviate from the standard technical recommendation in order to achieve a better fit between the two components, which required negotiating with the subcontractor to assume additional production risk. We based our cost optimization on using a single EPP molded part as both a thermal insulator and a carrier for most components (PCB, cable harnesses, fan) without the use of screws, minimizing the number of custom parts, and making maximum use of off-the-shelf components.

We recommended subcontractors to supply specific semi-finished products, while final assembly was entrusted to a company selected by the client. Our supervision included ensuring the integrity of the design and providing ongoing support in resolving assembly issues (e.g., a leaking gasket, a sagging glass panel), and we updated the technical documentation based on feedback from the production line. An experienced representative played a key role on the client's side; he had previously brought dozens of products to market and served as the primary point of contact between the contractors and us.

Helpbox 365 is Poland's first 24/7-monitored AED storage station, available around the clock, protecting the equipment from moisture, frost, heat, and dust. Centrum Ratownictwa has launched a nationwide initiative to install the first 100 stations in locations critical to public safety - in large cities, smaller towns, and rural areas. This project stands out in our portfolio as a combination of advanced electronics that communicate with a central management system and simple yet effective EPP technology - which we had not previously used in this product category.