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Project Details

Fabric 1

Bochini F/R PVC
Producer/Manufacturer: W Wiggins Ltd
Primary Use: Main Fabric

Fabric 2

Horse Lining RW500
Producer/Manufacturer: W Wiggins Ltd
Primary Use: Secondary Fabric

Fabric 3

Aqualoc zips
Producer/Manufacturer: QCD Ltd.
Primary Use: Hardware/Findings

Please describe the project specifications

In response to an existing client’s request, we developed a custom protective fabric bag for an advanced electric charging robot designed for large mining vehicles operating in the extreme conditions of the Arizona desert. The solution had to be UV-resistant, waterproof, dust-resistant, insulated, and highly flexible—while remaining lightweight and compact for storage.

The bag was constructed in two parts:
1. The main bag, which would cover the majority of the robot.
2. A separate cover for the end-effector, which contained multiple independently moving components.

We were quick to recognise the challenge — but we were ready to take it on.

The main bag was built from a series of panels, using a three-layer construction: an outer PVC layer, a middle layer of wool for insulation, and an inner PVC layer. As the layers were assembled, the bag became quite bulky. Weight became a concern, as the bag couldn't be too heavy—this would hinder the robot’s mobility. At the same time, it couldn't be too loose, as that would prevent it from folding and fitting into its designated container.

The most complex challenge was the end-effector, which had multiple components that slid, rotated, and moved independently in all directions. The bag for this part needed to be modular for easy removal and maintenance. All joins had to be both dustproof and waterproof, while still allowing for free movement of the robot parts.

Adding to the complexity, multiple fittings and refinements were needed as the robot design itself evolved during the project. We adapted to these changes and adjusted our design accordingly.

In the end, we successfully achieved our goal, delivering a solution that met all the project requirements. Mission accomplished.

What is unique or complex about the project?

This project stood out for its rare combination of environmental demands, engineering complexity, and evolving design parameters. Protecting a robotic charging system for mining vehicles in the unforgiving Arizona desert required a bespoke, high-performance fabric solution that was as adaptable as it was durable.

What made this job truly unique was the constant interplay between flexibility and precision. The end-effector’s independently moving parts required a modular cover system that could be easily removed for maintenance yet seamlessly sealed against environmental intrusion. At the same time, we had to respond to ongoing changes in the robot’s design—refining our patterning and fabrication in real-time to ensure a perfect fit.

This wasn’t just a cover—it was a tailored, technical skin for an evolving machine in one of the world’s harshest operational environments. The success of the project was a testament to our team’s ability to innovate, adapt, and deliver under pressure.

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