Client
Boot Buddy <www.bootbuddy.com>

Background
In 2016 Arminder Dhillon aged 15 became the youngest person ever to receive backing from three of the UK’s biggest and most established business people. Arminder created Boot Buddy aged 11 as an easy way to clean his football boots after getting fed up of being told off by his mother for bringing mud into the house. Seeking investment and guidance to help take his business to the next level, Arminder and his family braved the Dragons Den and secured backing from not just one but three dragons.

At Gemini prototyping we are proud to be part of Arminder’s journey. In 2014, Arminder and his family came to Gemini Prototyping with an idea and his own home-made prototype. It was clear to see that Arminder had created a great product, but he needed help taking the product to the next level. 

Challenge
We sat with Arminder and his family to understand more about his concept and what he wanted the product to achieve, this gave us all the information we needed to start supporting his vision. 

Gemini were the best fit for the project because they are the only European prototyping company that has injection moulding, blow moulding and ultrasonic welding in one facility.

The boot buddy team were new to product development and manufacturing so we escorted them through the entire process from design to mass production.

Gemini took the design concept and engineered it for manufacture. During this process we had to solve the following issues:

• Create an opening mechanism that could be easily operated with muddy hands.

• Develop an assembly process  which included ultrasonic welding and specialist clip designs to permanently attached parts together without adhesive.

• Create a blow moulding with two calibrated necks 

• Reduce component count.

At the subsequent prototyping stage we produced functional machined and printed models to prove out the design and produced aluminium prototype moulds and samples in the production intent materials. We could then commence pilot production of 10,000 units and manage mould development for mass production.

Result
At Gemini Prototyping it is important that we provide a service that goes above and beyond to all our customers and so we were delighted when we received the following from the team at Boot Buddy:

“Working with Gemini Prototyping is a true pleasure; Richard and his team go above and beyond to help and execute all project objectives in a timely and diligent manner. Gemini Prototyping are more than just a bunch of great engineers, they really become an extension of your team.

When working with Gemini Prototyping, you know you’re in very capable hands. Overall, we very happy with the work and projects carried out by Gemini Prototyping and look forward to continuing our work with Rich and his team in the future.”

Well done to Arminder and his family and from all the team at Gemini Prototyping we wish you all the success in the future.