Case study
Ultra-durable swing
hanger for Buglo

Need

A swing hanger smarter than gravity

Buglo faced the task of developing a new swing model for the UK market. The key technical challenge was to design and manufacture a rotary hanger that would meet exceptionally strict safety requirements. The new product had to offer very high abrasion resistance due to cooperation with other moving elements. Strength under large and variable loads and protection against adverse weather conditions were also crucial.

Since swings are used by both younger users and adults, the margin for error was absolutely unacceptable. It all came down to one thing: safety was the highest priority.

Additionally, the product had to meet the rigorous British standard while maintaining an attractive, competitive visual design for the UK market. The part must allow the swing to rotate freely around its own axis without the risk of blockage or the hanger wrapping around the structure. This stems from regulations in the BS EN 1176 standard — the European safety standard for playground equipment (equivalent to the Polish PN-EN 1176).

In practice, this meant that solutions approved for the Polish market, although compliant with local standards, were not sufficient to meet UK requirements. To illustrate the issue, imagine trying to spin 360° on a swing around its axis. A standard hanger would begin to wrap around the crossbar after a few rotations, causing blockage, potential device damage, or dangerous jerks to the seat. BS EN 1176 strictly prohibits this.

To prevent it, a special anti-wrap solution was necessary — technology that prevents the hanger from wrapping during full rotations. Thinking outside the box, Buglo, in cooperation with our design department, created a proprietary construction that meets these requirements without the need for complex and costly mechanisms known from advanced hangers.

Thanks to great collaboration and fast communication between our teams, Buglo prepared a model that our designers then adapted for efficient and safe serial production.

Solution

Fast injection mold — only better

Injection mold design for the hanger developed for Buglo.

In response to Buglo’s needs, the 3DForce team designed and built an injection mold enabling the production of a hook that meets the highest standards of strength and safety. We know how much work our clients put into preparing a design, especially for elements that must fit the overall product design in addition to their functionality. Sometimes a technology solution optimized at the design stage forces changes to the final appearance of the manufactured parts. Our team focused on reducing those differences to the absolute minimum.

For our team, unconventional orders and the challenges that follow are like solving an escape-room puzzle — and this time was no different. Both the design and the material selection posed challenges that had to be solved effectively in a short time. There’s a quote attributed to Albert Einstein that if he had only an hour to save the world, he’d spend 55 minutes defining the problem and 5 minutes finding the solution. Comparing injection-mold design to saving the world may be an exaggeration — but this time, time was critical, and we used similar criteria when selecting the material. Standard compounds were off the table.

The company owner himself got involved. Bartek first thoroughly analyzed the client’s needs. Then, drawing on his experience and contacts with reputable suppliers, he sourced a non-standard material perfectly aligned with the project requirements. The first recommendation presented to the client hit the mark. After the design and material were approved, we prepared a test batch. Several pieces went to the client for acceptance tests. The hanger passed them successfully — with no changes needed.

Thanks to efficient communication and a full understanding of Buglo’s needs, only 18 days passed from the first 3D model to delivering the finished product.

Key stages of the project

01 Technical analysis and geometry optimization

We conducted an in-depth analysis of the technical requirements and ensured the hook geometry was optimized for injection molding.

Thanks to this, the molten material fills the mold evenly, which results in:

• uniform material distribution,
• increased strength of the finished element,
• better surface aesthetics and finish.

Geometry optimization allowed us not only to meet functional requirements, but also to ensure high visual quality of the product.

02 Flow simulation

We ran detailed simulations of the material flow in the mold to eliminate potential structural weaknesses and determine the optimal gate location.

As a result:

• we avoided flow disturbances,
• we eliminated the risk of sink marks,
• we reduced any potential structural weak points of the part.

A properly planned material flow allowed us to achieve high quality and a uniform surface structure — directly improving the strength and reliability of the hanger.

03 Selecting the right polymer

We used a specially selected polymer with exceptional performance characteristics.

Thanks to this, the hanger gained:

• high abrasion resistance,
• excellent mechanical and sliding properties,
• outstanding resistance to changing weather conditions,
• durability enabling years of use under both high and low loads.

The material we chose is not commonly used in similar solutions, which further distinguishes our hanger in terms of strength and service life.

04 Injection mold design

From the start we followed the KISS principle (Keep It Simple, Stupid) — simplifying the construction to make it highly efficient, reliable, and easy to manufacture. The mold was designed to minimize process risks and eliminate the need for additional mechanisms, which significantly reduced production costs.

Additionally, with every design improvement we made sure to:

• preserve the client’s original design vision,
• limit the impact of process changes on the final appearance,
• ensure functionality and aesthetics go hand in hand.

Our designers understand how important it is that the final effect doesn’t deviate from the initial concept — so every change was carefully analyzed, consulted, and implemented with full respect for aesthetics.

05 Test batch verification

Before starting serial production, the client received a test batch of parts.

This is a standard stage ensuring full quality compliance with the client’s expectations and technical documentation.

At this stage we:

• delivered an agreed number of test pieces after our internal quality control,
• the client performed their own tests and evaluation,
• after a positive acceptance test both parties approved a physical master sample,
• the approved pattern went straight to the production line.

This process ensured both sides were confident that the final product meets all the intended requirements — technical, functional, and aesthetic.

Results

High quality and safety

The new hanger meets all durability and safety requirements in line with rigorous standards.

Preserved original design

We maintained the visual effect developed by the client despite necessary process changes.

Avoided a costly solution

Instead of an expensive, complex mechanism, we created a dedicated, intelligent hanger.

Fast rollout to a compliant market product

Rapid execution enabled swift testing and introduction of the product to the offer.