Project: Light City Buses- Brake Hub Removal Tool

Client: Transfield Services/Broadspectrum

Design, manufacture and certification of an award winning custom prototype brake hub lifting tool to mitigate manual handling risks.

Nylastex was approached by the Operation Manager of the Light City Buses Contract to design and certify a brake hub removal tool, in light of identified manual handling risks in three of their workshops.


The need for a custom solution came about after three, separate, minor injuries occurred, all during the process of changing brake rotors on Scania buses. At Broadspectrum, part of a Diesel Mechanic’s task is to remove Brake Hub Assembly to change or replace brake pads. The previous process was for two mechanics to bend and reach under the wheel arch to remove the brake hubs which weigh approximately 50kgs. This process increased the risk of manual handling related injuries due to the awkward position the mechanics must undertake and the weight of the hub which they are lifting.

Led by Geoff Philips, the Nylastex team got to work, designing, manufacturing and certifying a custom brake hub removal tool for the project. The tool involved engineering a bracket on a trolley jack so that the bracket could be positioned to the hub and secured so it could be easily transferred by the trolley jack. The trolley jack is capable of lifting up to 2,000kgs. This process negated awkward body positions and eliminated lifting, bending and twisting.

“Not only did the engineering of a lifting tool eliminate manual handling, it also allowed the job to be a one person task and reduced damage to inner lip seals, therefore increasing efficiency and productivity.” – (Heath Jenner – Light Bus Services Operation Manager).

The custom Brake Hub Removal Tool was soon taken up by two additional bus contractors in South Australia to effectively reduce their manual handling risk and to improve efficiency.

Furthermore, The final design went on to win the SISA award, “Best Work Health & Safety Solution”, awarded for the best example of an innovative solution to an identified workplace hazard.

Nylastex is highly experienced and qualified in the design, manufacture and certification of special purpose-built equipment for projects spanning a variety of industries. To learn more about this capability, click here:


Project: Light City Buses Contract- Engine Changeover Project

Client: Transfield Services/Broadspectrum

Design and certification of cutting edge, purpose built workshop equipment to reduce the turnaround time for bus engine rebuilds.

Nylastex was first approached by the Operations Manager (insert name?) of Light City Buses, to assist in reducing the turnaround time for bus engine rebuilds.

Prior to approaching Nylastex, Light City Buses was struggling to deliver the crucial bus services required to service Adelaide under the Adelaide metro network. This was due to a high volume of long term stopped buses due to engine failure that required an engine rebuild, which on average, took 4-5 weeks for the workshop to facilitate before the buses could return to service.

With the key goal of significantly reducing turnaround time for engine rebuilds, the Nylastex team got to work, playing a pivotal role in the engineering design and certification of purpose built equipment. In particular, the Nylastex engineering team designed and certified five different types of engine cradles and engine stand mounts, in addition to two purpose built rotating engine stands.

“Nylastex enabled us to safely reduce the physical changeover time to 45 minutes, that is engine in, engine out”. By taking all of our internals to externals, we were able to take the average time for a stopped bus from 4-5 weeks to 3 days consistently. These changes delivered on safety, service requirements and bottom line results.”

“Without the support and expertise of Nylastex throughout the project, we could not have achieved such an outstanding result”.

Nylastex is highly experienced in the design and manufacture of special purpose-built equipment for a variety of industries. To learn more about this capability, click here:

Project: Multi Cavity Plastic Injection Mould for Flip-Over Lid

Client: Confidential

Nylastex was commissioned to develop, design and manufacture an eight cavity tool, with complex tightly tolerance parts for a global skincare brand.

In 2020, after several attempts to find a suitable Toolmaking company within Australia with the capability and knowledge to produce quality plastic injection moulds, Nylastex was commissioned to develop, design and manufacture an eight cavity tool, with complex tightly tolerance parts for a global skincare brand.


The technical challenge in respect of the tool designs stemmed from:

  • The complexity of the part shapes (including a hinge and an internal thread with a unique thread profile);
  • The extremely tight tolerances;
  • The flow of the material through the multi cavities
  • Ejection issues in respect of the unscrewing core to eject the part without damaging the thread
  • The design of a bespoke in-mould closing mechanism to automatically close the flip-top cap prior to ejection.

Prior to commencing Geoff Philips, Managing Director reviewed the design brief and confirmed the requirements in consultation with the client and the Nylastex in house tool design team.  The main hurdle to overcome was whether an electrically driven bespoke in-mould closing mechanism could be created to automatically actuate the self-closing of the flip-top cap post injection prior to the starting of the ejection sequence. The part could then be seamlessly released from the mould in its closed state.   In this respect, the challenge was to determine the geometric and dimensional tolerance and sequencing of the closing arms to minimise stroke distance required for closing as well as the force that needed to be exerted by the servo drive to effectively snap the flip top cap closed. This calculation had to take into account a range of variables including the material’s elastic modulus, maximum strain and stress within its elastic region and the part geometry.

The hypotheses were first tested within the framework of computer aided design tools and then through the design, building and testing of a physical tool.

Nylastex was able to overcome the design and manufacturing challenges and have the tool into production within the timeframe required.

Nylastex has managed to grow its business by committing to the philosophies of innovation and continuous improvement and developing niche capabilities in plastic injection moulding and custom engineering.


Project: Medical Face Mask production

Client: Detmold Group

The Nylastex team assisted the Detmold Group with the installation and commissioning of a face mask factory within their Brompton facility. 

The Nylastex team was approached at the beginning of the Covid-19 pandemic in March 2020 to assist the Detmold Group with the installation and commissioning of a face mask factory within their Brompton facility.

We worked closely with the Detmold Engineering Group to install newly purchased equipment, fixing and fine tuning any issues to get them up and running as quickly as possible.  Within 16 weeks from equipment order 750,000 masks were being produced each day.   Once up and running our in-house design team, working alongside the General Manager and Engineers from Detmold, made the necessary changes and improvements to meet the quality requirements of the TGA.  Changes included redesigning and manufacturing the nose wire delivery unit, nose forming anvils, earl loop weld anvils, side loop anvils, weld anvils and rotary knives.

By working with our customer we were able to supply a solution and help them reach their production target of supplying 1,000,000 medically-approved masks to SA Health and other Government Departments both within SA and interstate.

Nylastex was chosen for this project for several reasons.  Firstly because of their in-house design team, machining and manufacturing capability. Secondly because of their previous knowledge and experience in manufacturing and modifying Special Purpose Built Equipment.  And thirdly because of their quick response to the Covid-19 pandemic and willingness to split their team into two groups.  This reduced the risk to their employees while still ensuring ongoing support to their customers.