Back to case studiesCustom 3D lightpipe with structural support and illuminated branding.
Market Background
The market for terrestrial modems, particularly for satellite communications networks, is rapidly growing. These devices serve as critical infrastructure for reliable, high-speed internet and television services, often in challenging environments. As competition intensifies, manufacturers strive to differentiate their products with innovative features and premium designs that cater to both functionality and aesthetic appeal.
Customer Challenge
A leading manufacturer of set-top boxes for satellite communications approached VCC with a unique challenge. They envisioned integrating a custom indicator into their terrestrial modem enclosure that not only displayed the modem’s status but also reflected their forward-thinking design ethos.
Set-top box manufacturers today face the dual challenge of competing with integrated Smart Televisions and dedicated, low-cost Over-The-Top (OTT) streaming players that often offer superior, flexible application ecosystems.
As for modem enclosures, it has a complex technical trilemma that balances thermal management, Radio Frequency (RF) transparency, and Electromagnetic Compatibility (EMC). Which means, this is not an easy challenge for VCC.
The constraints of the modem enclosure’s geometry required a custom lightpipe solution capable of:
1. Ensuring uniform illumination for clear visibility of the modem’s status.
2. Supporting itself structurally during assembly, freight, and installation, without requiring additional components.
3. Maintaining a premium design aesthetic that aligned with the customer’s brand image.
This complex requirement demanded a solution that balanced cutting-edge design with practical engineering.
Our Solution
VCC collaborated closely with the customer to transform their prototype concept into a fully realized, custom 3D lightpipe design. Leveraging advanced simulation tools, VCC was able to:
• Validate the uniformity and efficiency of the lightpipe’s performance in virtual prototypes.
• Optimize the lightpipe design to seamlessly integrate into the enclosure without requiring additional support structures.
• Reduce time and costs typically associated with multiple physical prototype iterations.
The solution featured an illuminated logo design that blended functionality with aesthetics, elevating the customer’s brand presence in the market.
Result & Benefits
The custom lightpipe exceeded the customer’s expectations, delivering:
• Enhanced Product Differentiation: The illuminated logo design reinforced the brand’s reputation for innovative, premium products.
• Cost Savings: By incorporating structural support directly into the lightpipe, additional tooling investment was eliminated.
• Streamlined Production: The efficient design simplified assembly and reduced the risk of damage during shipping and installation.
• Quantifiable Improvement: VCC’s design was a 298% improvement in efficiency above the customer’s design, and 49% improvement in uniformity ratio.
This collaboration underscored VCC’s ability to turn ambitious design visions into practical, high-performing solutions.
Conclusion
By partnering with VCC, the customer successfully brought a unique and innovative modem set-top box to market. The custom indicator lightpipe not only met their stringent functional requirements but also enhanced the overall user experience, setting a new benchmark in their industry.
