Optic Drive is equipped with a camera, tilt control and a built-in screen, empowering users to handle screws as small as M1 (1 mm in diameter). Designed by Constantin Schott and Rohith Rajesh Kumar.
Next generation low torque assembly
Methodology in Product Design (APD1)
2025
This project was carried out in close collaboration with Atlas Copco, a market leader in high-quality, precision assembly solutions for low-torque screw tightening across sectors such as consumer electronics, semiconductors, medical electronics and vehicle electronics. Accurate screw tightening is an essential component of manufacturing, providing a reliable and efficient way to secure objects together. In electronics, precision is paramount, and accurate tightening plays a crucial role in maintaining both cost-efficiency and quality. Although electronic devices are becoming smaller, the number of screws used remains high. For example, an average smartphone that fits neatly in the palm of the hand can still contain up to 70 screws. The growing demand for electronics in everyday life, combined with these large quantities of screws, increases the complexity of low-torque manufacturing and introduces significant challenges.
Process
The objective was to generate next-generation concept proposals aligned with Atlas Copco’s low-torque assembly portfolio within a 5–10-year horizon. This was achieved by exploring new and emerging hybrid production models alongside traditional and automated manufacturing methods. The designs were required to prioritise the needs of different users and to incorporate core values such as safety, precision and ergonomics, reflecting the company’s position as a premium brand.
The project began with a research study trip to the Atlas Copco Tools Innovation Center in Bratislava, Slovakia. This provided an opportunity to examine current product offerings at close range, explore and test solutions, ask questions, and document existing systems through photography and film. The students then divided into four smaller groups to visit different customer sites in Czechia, Hungary and Romania. These visits offered a valuable opportunity to observe professional environments and the assembly procedures currently used in industry.
Outcome
The project resulted in nine conceptual proposals exploring the future of low-torque assembly, focusing on the evolution of current practices through automated, hybrid and manual tightening supported by intelligent systems.
The project kicked off with a study trip to the Atlas Copco Tools Innovation Center in Bratislava, Slovakia, followed by customer visits in Czechia, Hungary and Romania. Video editing by Aryaman Kashyup
PGL+ bridges the gap between entry-level and mid-range screwdrivers in the Atlas Copco product portfolio, delivering on quality, ergonomics and process reliability. Designed by Benedikt Herzau and Johanna Huse.
The Smart Balancer SB01 and the Smart Feeder SF01, when combined, deliver high-quality tightening through one smart system, instead of three separate low-end screwdriver setups. Designed by Brandon Escalona and Pascal Stappen.
Mimic combines the rigidity and accuracy of robotic automation with the fluidity and critical thinking of the human mind by offsetting the weight of the tool. Designed by Aryaman Kashyup.
The Lumi system is an AI-powered companion that lives on the assembly line. Attached directly to standardised T-slot extrusions, it provides real-time projected guidance. Designed by Clara H Germann and Viktor Strömberg.
Capture is a wearable, on-the-spot camera that helps operators document everyday micro-frictions and opportunities for assembly floor improvements, such as awkward reaches, missing parts and poor lighting. Designed by Emily Klein.
Sense is a product–service hybrid that helps manufacturing teams understand their assembly line performance, translating real-world data into clear, actionable recommendations for optimisation. Designed by Marija Kucurski and Murat Can Habire.
The TorqueSync System is a modular screw-feeding system that automatically verifies the inserted bit, guides operators to the correct screw source, and prevents mismatched operations. Designed by Zhiyuan Jiang.
RTR-01 is a complete repair system featuring a smart screwdriver and arm, an automatic bit-changing station and service software for step guidance, documentation and traceability. Designed by Tejas Mitra.
