Megapro Industrial Design Case Study (Ratchet Driver)

White Box Design’s latest product design with Vancouver’s Megapro is the professional grade ratchet driver.

It incorporates all the tried and true features of Megapro’s existing products with new advancement in ergonomics (tapered comfort grip) and features a new ratchet mechanism.

The Challenge

– Visually
1. Build on and evolve Megapro’s existing visual brand language
2. Look more contemporary, “the ultimate professional driver”

– Usability/ergonomics:
1. More comfortable in the hand
2. Incorporate grip/texture

-Size & Functionality
1. Maintain overall diameter to fit bit cartridge
2. Incorporate the key Megapro features
3. Add ratcheting mechanism

Concept Sketches

A sample of the exploration sketches that incorporate the key challenges

Early CAD models and Form Validation

Next step is to develop the chosen direction into the virtual world, using CAD we bridge the design with the overall mechanical requirements. Making sure internal elements can fit inside the design with appropriate wall thicknesses.

After developing the design further a prototype is made to test how well it really works (fit, comfort and form).

Mechanical Development

Now for the fine tuning, White Box Design hands off the design intent files to the mechanical engineer to further develop and detail for manufacturing. The mechanical engineer validates overall dimensions and details each component for moulding.


The final design and CAD files from mechanical engineer are supplied to the toolmaker. The toolmakers machine shop uses CNC machines to make the injection molding tools.


With state of the art equipment and a demand for high quality and high tolerance parts, the entire driver is moulded and assembled locally.

The Final Product

Shipping Drivers optimized in shipping boxes