Jump Starter
Maintaining design standards for premium automotive brand
Snap-on Tools
Client: We partnered with an OEM supplier to Snap-on Tools to develop a new generation of a widely used professional vehicle jump starter. Designed for demanding workshop environments the updated product needed improved durability, safety and visual presence while maintaining familiarity for existing users. The project focused on redesigning the outer enclosure, protecting internal components from impact and introducing additional electrical safety features, supporting a more robust and reliable solution for daily use by professional mechanics.
Approach: We delivered a full product redesign programme covering styling, mechanical engineering and durability-focused technical improvements. We developed a new enclosure design and created an internal suspension system to protect the battery from impact during transport and use. A new isolator switch was integrated to improve operational safety. Rapid iterations using in-house 3D printing enabled fast evaluation of concepts and supported functional development prior to tooling.
Challenges: The jump starter operates in harsh workshop environments where drops, vibration and repeated handling are routine. The isolator switch required exceptional durability and reliability, while the enclosure needed to protect critical internal components without increasing bulk or complexity. Ensuring robustness aligned with the Snap-On Tools brand while supporting manufacturability was central to the project.
Deliverables: We delivered enclosure restyling, internal protection architecture and integration of a new isolator switch to improve safety and reliability. We designed and built bespoke durability test rigs to cycle switch and clamp assemblies up to 100,000 uses. Pd-m also supported tooling development and worked closely with manufacturing partners to prepare the product for production.
Impact: The redesigned jump starter improves safety, durability and resilience for professional workshop environments. By strengthening protection of internal components and introducing an isolator switch, Pd-m helped enhance product reliability and user confidence while supporting efficient transition from development into manufacture.
“Being trusted to develop a new product for such a world renowned brand was a huge responsibility, but something we were highly capable of doing. The team at Pd-m really demonstrated our capability in design, engineering and manufacture to maintain the high quality which the client expects.”