Our Approach
3fD reframed the challenge: instead of focusing on circumventing patents, we tackled the core technical problem — energy transfer efficiency.
By engineering a new patentable steam generation system, we:
- Developed an instant steam engine with a pulsed delivery method, rapidly heating hay to pasteurisation temperatures.
- Reduced water and energy consumption while significantly improving cycle times.
- Delivered not just technical efficiency, but also a user-focused, ergonomic design suited to harsh, outdoor environments.
Engineering & DFM Decisions
- Steam System: Created a pulse-driven steam delivery method, delivering immediate, high-intensity heating for faster pasteurisation.
- Material Choice: Selected expanded polypropylene (EPP) for its resilience, thermal insulation, and lightweight properties — outperforming traditional rotomoulded plastics in durability and usability.
- User Experience: Integrated an electronic control interface with full software-driven functionality, including auto descaling for low-maintenance ownership.
- Weatherproofing & Durability: Engineered a robust construction to withstand outdoor exposure, UV degradation, and mechanical stress.
Outcome
- Developed a patentable technology that positioned Sanderson at the forefront of the market.
- Achieved industry-leading efficiency, cutting water and energy use while reducing cycle time.
- Delivered a rugged, user-friendly product that enhances customer satisfaction and operational reliability.
- Positioned Sanderson as a premium brand in the equine health market, with growing sales and strong market adoption.
What We Learned
Reframing technical challenges leads to category-defining innovation. By focusing on the core problem — energy transfer — rather than IP workarounds, we delivered a superior solution that outpaces the competition in both performance and design.
