Cox Powertrain

Cox Powertrain

Cox Powertrain (www.coxmarine.com) is a leading, UK-based engineering firm which produces cutting-edge diesel engines for a global market.

Having previously produced an exhibition display unit for Cox to showcase a range of engine throttles, autopilots and steering wheels, the company approached us with a fresh challenge.

They were developing a revolutionary new product, the CXO300 – the most powerful diesel outboard engine in the world – specifically for commercial and government use, to deliver outstanding power, reliability, durability and fuel efficiency.

The Cox team wanted us to help them with a critical aspect of developing this ground-breaking new engine, enabling them to fine-tune the design before any parts were finalised and manufactured. They asked us to fabricate a flow test model for the top section of the prototype, so they could assess the engine’s aerodynamics and waterproofing properties.

After getting very expensive quotes from a number of product design model makers to produce the prototype, we realised we had to find a much more cost-effective solution. A call-out to our extensive network of suppliers led us to a freelance model maker who, using the same techniques and materials, could supply the finished model at a fraction of the cost.

Based on a 3D computer model of the new engine design, we had 5-axis CNC machine models milled from resin. These milled ‘plugs’ give a highly accurate representation of the engine’s external and internal surfaces and components. From these, the top shell and internal elements were fabricated from fibreglass, acrylic and machined steel. The clear side panels (which will be steel in the finished engine) were added so the air and fluid flow could be seen from the outside.

Cox engineers were then able to use the completed model for bench testing, using air flow jets and coloured smoke to evaluate its aerodynamic properties. This allowed them to make small but crucial adjustments to the internal surfaces (using modelling clay) to perfect the design prior to final tooling and, ultimately, manufacture of the production engine.

The huge network of suppliers and industry contacts we have built up over the last 30 years made it possible for us to help Cox develop an exciting new product without the massive overheads normally associated with such a project. That was great news for our client but also for us at Toolshed, as it enabled us to take on a different kind of challenge which sat firmly outside our normal areas of work.