1. Introduction

Modern logistics is increasingly focused on automation and the optimization of packing processes. In distribution centers, the precise placement of IT equipment plays a crucial role in ensuring high operational efficiency. Incorrect mounting of devices increases the risk of equipment damage, complicates access for IT and Facility departments, and reduces workstation ergonomics.

A logistics company approached Xtrude3D with a challenge—designing dedicated mounts for Thin Clients and MiniPCs. The primary requirement was to create a solution that allows for quick and stable installation of devices, both on aluminum profiles and directly onto the packing station surface. An additional challenge was the need for rapid delivery of ready-to-use components, which required an accelerated design, testing, and production process.

In this case study, we will demonstrate how Xtrude3D developed and implemented functional mounts that met all customer requirements in terms of ergonomics, durability, and operational efficiency.

2. Client's Business Challenge

A logistics company undertaking the project was implementing new packing stations in its distribution center. As part of this modernization, dedicated mounts for Thin Clients and MiniPCs needed to be installed at workstations. The client required a solution that would provide secure and stable device mounting, while also ensuring easy access for IT and Facility departments and optimizing workplace ergonomics.

Key Requirements and Challenges to Solve:

• Stable Mounting for Thin Clients and MiniPCs – The mount was designed for devices with 70x70 mm mounting holes, compatible with M3 screws.
• Three Distinct Mounting Designs –
  
  1. First solution designed for mounting on 40x40 T-Slot aluminum profile (slot 8).
  2. Second solution for mounting on 40x80 T-Slot aluminum profile (slot 8).
  3. Third option allowing direct attachment of the mount to the packing station tabletop and other workstations within the distribution center.
• Resistance to Warehouse Conditions – The working environment, subject to continuous vibrations caused by warehouse operations, required a durable and reliable mounting system.
• Ergonomic Cable Management – The mount was designed to eliminate the risk of cable damage while maintaining a clutter-free workspace. Additional mounting elements were developed for managing cables on both aluminum profiles and tabletops.
• Easy Access for IT & Facility Management – The system needed to enable quick device removal for maintenance or replacement.
• Ultra-Fast Implementation – Due to a tight deployment schedule, the first fully functional prototypes had to be ready in under 5 days. Additionally, the final production and delivery to the client had to be completed within less than 24 hours after project approval.

Given the high operational dynamics and strict deadlines, the client required a partner capable of quickly analyzing requirements, designing a solution, conducting tests, and delivering the final product without delays. Xtrude3D took on the challenge, developing three dedicated mount systems that met all key client requirements.

3. Implementation Process

After thoroughly analyzing the client’s challenges and requirements, Xtrude3D took action to design and deliver the most optimal solution within the shortest possible timeframe. The key stages of implementation included detailed analysis, rapid CAD design, prototyping, and express production and delivery.

3.1 Client Requirements Analysis

The first step was an in-depth analysis of the client’s operational and technical needs. During consultations with the team responsible for the implementation of new packing stations, the following key requirements were identified:

• Three independent mounting variants –
  
  • A mount for 40x40 T-Slot aluminum profiles (slot 8).
  • A mount for 40x80 T-Slot aluminum profiles (slot 8).
  • A mount for direct installation on the packing station tabletop.
• Use of vibration-resistant materials – The mounts needed to withstand impacts and heavy use in a warehouse environment.
• Fast deployment as a priority – The client required instant prototyping and delivery, reducing any downtime in operations.

3.2 Rapid CAD Design

Using Fusion 360, Xtrude3D quickly developed five variations of the mounts, considering various mounting configurations and specific client needs.

• The designs were optimized for mechanical strength while maintaining compact dimensions, allowing for easy integration into the packing station layout.
• Parametric modeling was utilized, enabling quick adjustments based on client feedback and specific IT device requirements.
• Strength analysis was conducted on each design to ensure the stability of the mount under intensive warehouse conditions.

3.3 Express Prototyping

Once the CAD designs were approved, immediate prototyping was initiated using 3D printing technology. The goal was to quickly test the functionality of the mounts in real working conditions.

• The first prototypes were delivered to the client within 24 hours after starting the design phase.
• The prototypes allowed for mounting tests, ergonomic evaluation, and structural stability analysis.
• Based on client feedback, final design refinements were made before moving to full-scale production.

3.4 3D Printing in FDM Technology – Materials & Production Method

The final mounts were manufactured using Fused Deposition Modeling (FDM) 3D printing, ensuring precision, speed, and cost-effectiveness.

• Material of choice: PET-G – Chosen for its high mechanical strength, vibration resistance, and chemical durability, making it ideal for logistics environments.
• The mount design was weight-optimized, reducing printing time while maintaining strength.
• The use of PET-G ensured a balance between durability, flexibility, and production speed, meeting all client expectations for long-term operational stability.

3.5 Rapid Delivery & Warehouse Implementation

The final versions of the mounts were produced and delivered to the client in record time.

• The entire process, from initial consultation to final delivery, was completed in less than a week.
• Production and shipping were completed within 24 hours of the client’s approval.
• The client received a fully assembled mounting kit, allowing for immediate installation at packing stations without additional modifications.

Thanks to advanced design and manufacturing technologies, Xtrude3D delivered customized mounts that met all operational requirements, while also minimizing the deployment time to an absolute minimum.

4. The Final Solution and Its Benefits

After a detailed analysis and rapid project execution, Xtrude3D successfully delivered three dedicated mounting systems for Thin Clients and MiniPCs. Each solution was designed to meet the operational requirements of the logistics center, ensuring stability, ergonomics, and ease of installation.

4.1 Final Solutions – Delivered Mounts and Their Key Features

Xtrude3D developed three distinct mounting systems, each adapted to a different installation method:

1. Mount for T-Slot 40x40 and T-Slot 40x80 Aluminum Profiles

• Designed for quick attachment to the workstation frame made of aluminum profiles.
• The robust structure ensures resistance to vibrations and impacts, which are common in distribution centers.
• Adjustable positioning allows the Thin Client or MiniPC to be installed at an optimal location based on operational needs.

2. Under-Desk Mount for Packing Stations

• Compact mounting system allowing direct attachment under the packing station’s tabletop.
• Hidden installation, optimizing space while protecting the device from accidental damage.
• Easy service access, enabling IT teams to quickly replace or maintain devices.
• Pre-drilled mounting holes, precisely matching the standardized IT equipment used by the client.

4.2 Why These Mounts Stand Out

Both solutions were manufactured using FDM 3D printing technology with PET-G material, ensuring durability and resistance to warehouse conditions:

• High mechanical strength – withstands constant vibrations, shocks, and operational stress.
• Chemical resistance – protects against exposure to cleaning agents or industrial solvents.
• Optimized weight and structure – reducing material usage while maintaining full structural integrity.

By leveraging PET-G, Xtrude3D delivered a cost-effective and robust solution that perfectly aligned with the client’s logistics operations and long-term usability goals.

5. Benefits of the Solution for the Client

The implementation of dedicated Thin Client and MiniPC mounts delivered by Xtrude3D significantly improved ergonomics, durability, and operational efficiency at the client’s logistics center. The optimized design of the mounts provided several key advantages, enhancing workplace organization and reducing maintenance costs.

5.1 Optimized Equipment Placement

The new Thin Client and MiniPC mounts allowed for better workspace organization, ensuring that employees had unobstructed access to tools and materials.

• The under-desk mount freed up workspace, eliminating obstructions from the work surface.
• Aluminum profile mounting solutions enabled flexible device positioning, adapting to specific workstation requirements.

5.2 Increased IT Equipment Durability Through Vibration Reduction

The mounts were designed to minimize vibrations caused by warehouse operations, reducing the risk of device damage and operational failures.

• Strategic positioning of the mounts in less exposed areas helped protect Thin Clients and MiniPCs from accidental impacts.
• Integrated cable management elements reduced the risk of cable damage and improved workstation organization.

5.3 Faster Access for IT Maintenance

The new mounting solutions allowed for quick removal and reinstallation of devices, significantly benefiting IT and Facility Management teams.

• The design provided unrestricted access to cables and ports, shortening service times.
• Devices could be swapped out without disrupting operations, reducing downtime for critical workstations.

5.4 Efficient Cable Management

The mounts included dedicated features for cable routing, eliminating loose or exposed cables that could interfere with operations.

• Improved aesthetics and workplace safety by preventing tangled wires.
• Minimized risk of accidental disconnections or damage during daily tasks.

5.5 Immediate Deployment Readiness

One of the key advantages of Xtrude3D’s solution was the rapid turnaround time from design to delivery.

• The entire project – from consultations to testing and final production – was completed in less than a week.
• Final mounts were delivered within 24 hours of project approval, allowing the client to immediately implement the solution with no delays.

By leveraging cutting-edge 3D printing technology and engineering expertise, Xtrude3D provided a custom solution that not only improved workstation organization but also enhanced IT equipment durability and operational efficiency.

6. Conclusions and Impact on the Client’s Operations

The implementation of custom Thin Client and MiniPC mounts in the client’s distribution center delivered measurable operational and financial benefits. Xtrude3D provided a tailored solution that met all technical and ergonomic requirements, significantly improving workstation organization and overall operational efficiency.

6.1 What Results Were Achieved?

1. Improved Ergonomics at Packing Stations

By implementing three mounting variants – for aluminum profiles and under-desk installation – the client optimized workstation space utilization and operator comfort.

• Employees gained better access to IT devices, leading to higher efficiency in daily tasks.
• The under-desk mount freed up space, reducing clutter on the work surface.

2. Enhanced IT Equipment Durability

Stable mounting eliminated vibrations and shocks, protecting Thin Clients and MiniPCs from damage during warehouse operations.

• Reduced risk of hardware failures minimized maintenance and replacement costs.
• Cable management solutions prevented accidental disconnections or damage.

3. Minimized IT Maintenance Time

The new mounts enabled quick and easy device removal, significantly reducing downtime for maintenance and repairs.

• IT and Facility Management teams could access and replace devices faster, ensuring uninterrupted workstation performance.
• The design provided unrestricted access to cables and ports, further streamlining maintenance procedures.

Did the Solution Meet Expectations?

The custom mounts fully met the client's technical and operational needs. After implementation, the client confirmed that:

• The mounts provided stable and durable device installation, even under high-intensity logistics operations.
• Workstation setup became faster and more intuitive, improving overall workflow efficiency.
• Space optimization allowed for better workstation organization, without compromising productivity.
• Rapid production and delivery enabled immediate integration, with no operational delays.

What Time and Cost Savings Were Achieved?

1. Reduced IT Maintenance and Replacement Costs

• Eliminating vibration-related hardware failures decreased service and replacement expenses.

2. Increased Packing Station Efficiency

• Better workspace organization and cable management allowed operators to work more efficiently, free from equipment obstructions.

Long-Term Benefits for the Client's Operations

1. Durable and Versatile Solution

• The mounts were designed to be adaptable to different device models, allowing the client to reuse them during future IT upgrades.

2. Better Workstation Organization

• Optimized device placement and structured cable management improved worker comfort and reduced operational errors.

3. Reduced Downtime in Logistics Operations

• Faster access to IT devices and simplified maintenance lowered the risk of unplanned interruptions, which is critical in high-intensity distribution centers.

4. Cost Savings Due to Reduced Equipment Damage

• Stable mounting solutions and vibration protection extended IT device lifespan, minimizing long-term investment costs.

Summary

By implementing custom-designed Thin Client and MiniPC mounts, Xtrude3D provided the client with a durable, ergonomic, and efficient solution that enhanced workstation organization, improved IT hardware longevity, and reduced maintenance costs.

The solution was not only effective for immediate use but was also future-proof, allowing the client to adapt it for upcoming IT hardware upgrades.

This case study demonstrates that advanced 3D printing technology enables fast and effective responses to specific operational challenges, ensuring high-quality, customized solutions with rapid turnaround times.