Shellshock

Design Anthology was engaged to solve a complex challenge: designing a rugged, modular enclosure to house high-performance computers, helping SAPHI drastically reduce development timelines for bespoke solutions. Beyond meeting IP67 compliance and protection against dust, water, vibration, and heat, the solution had to support easy customisation, quick assembly, and minimal tooling investment, without compromising commercial viability or aesthetics. The result unlocked operational efficiencies, allowing SAPHI to remain focused on optimising AI capabilities. It also laid the groundwork for a strategic pivot, leveraging their deep industry expertise into a scalable, product-based business model.

Design Anthology took a phased, evidence-led approach, moving from concept sketches through detailed design to high-fidelity prototypes. The solution features a custom extruded aluminium body for rugged heat management, vibration isolation, and IP67+ protection. A removable backplane streamlines assembly and servicing, while modular, stackable enclosures adapt via interchangeable end caps for varied I/O needs. Shellshock supports edge AI deployments, remote management, cloud syncing, extending lifecycle and usability. Early prototypes validated thermal performance, tolerances, sealing, assembly, and cable routing under real-world stresses. The outcome: a manufacturable, user-friendly, highly customisable platform, enabling SAPHI to launch, market, and scale faster than ever.

Shellshock positions SAPHI to commercialise a high-quality, industrial-grade enclosure that improves safety, reliability, and operational efficiency across mining, government, transport, defence, infrastructure, and manufacturing. Its rugged, modular design reduces reliance on fragile enclosures, enabling the latest technology to be deployed without redundancy and accelerating product development. Environmentally, Shellshock extends product life, reduces waste through reusable, serviceable components, and improves asset management and resource optimisation. Commercially, it empowers SAPHI to scale confidently, leveraging the best-suited tech stack into existing and new markets while elevating brand credibility. Societally, it broadens access to advanced, robust technology, optimising efficiencies and improving safety.

Shellshock balances industrial strength with refined design. Its 6060T6 aluminium extrusion acts as both structure and heatsink, offering corrosion resistance, impact durability, and thermal efficiency. Internal vibration mounts safeguard sensitive hardware during transit and operation. Each unit features a removable backplane for pre-assembly and bench testing, while customisable end caps with O-rings support cable glands, IP-rated connectors, or branding options. Colour, finish, and laser-etched graphics can be tailored for white-labelling, enhancing product value with minimal extra cost. Shellshock supports base, wall, and pole mounting, with scalable thermal upgrades including fans or copper heatsinks for high-performance builds. Its flexible design enables technology-specific customisation, reducing rework, avoiding poor fit, and minimising redundancy. For end users, the benefits are clear: fast installation, easy servicing, and minimal setup overheads, ultimately accelerating hardware development and cutting time to market. Drawing on Design Anthology’s expertise in military and industrial product design, Shellshock is the result of a holistic approach to manufacturing methods, serviceability, branding, and environmental durability, delivering a modular, low-tooling, and high-impact industrial platform.