Cambridge Consultants has developed a new range of innovative Ironing products using SolidWorks for LAURASTAR, the worlds leading innovator in ironing systems.

The new iron delivers a professional, long-lasting finish whilst reducing ironing times by up to 50%. Steam is used in irons to penetrate fibres and knock out creases in fabric. However, damp fabrics are just as likely to crease again so the fabric needs to be 'set' by a further application of dry heat.

The new automatic steam function works by delivering twice heated steam automatically, at a pressure of 3.5 bar, the instant the iron detects forward motion. However, the steam shuts off as soon as the iron stops moving or is used in a reverse motion.

This smart steam feature removes creases and sets the fabric in a single ergonomic action. The inclusion of a ventilation system built into the ironing board allows the iron to ride across fabrics on a wave of air which further helps prevent creasing and eliminate steam marks. The direction of the blower can be reversed so that clothes, such as trousers, can be held to the board to achieve a more precise crease.

In developing the new technology within the iron, Cambridge Consultants considered a range of sensing technologies and quickly rejected the obvious options such as optics and accelerometers as they were unable to deliver the real-time performance required.

Instead Cambridge Consultants settled on a sensing arrangement based on two half-bridge strain gauges built into the iron's handle. When coupled with a purpose designed control system, the iron is able to rapidly detect movement, starting or shutting off steam production within a millisecond. To the user, there is no apparent time delay between moving the iron and the steam turning on or off. The real-time control system gives the iron a sense of intelligence to know exactly how it is about to be used and to safely deliver steam at the appropriate moment.

One of the design challenges for Cambridge Consultants was how to install the new technology without impacting the product styling and ergonomic feel that is so critical to LAURASTAR's leading position in the ironing market.

A key concern was the impact that additional cabling for transmitting control information between the iron and the steam generation unit might have. Cambridge Consultants provided an elegant answer to this challenge by developing a low cost circuit that transmits the necessary control data on the existing power supply cable using a special data modulation technique. This approach allowed LAURASTAR to continue using its well-proven 'mono-tube' cable, which is optimised for ideal ironing.

Eric Wilkinson, Cambridge Consultants' director responsible for the project added, "This project shows how the use of advanced electronics can open up markets across a range of consumer goods. In just under a year, I believe we have created a product that leaves you wondering why all irons don't work this way."