Lex Products, a company that makes power distribution boxes for military and commercial use, came to us to figure out a new design that would allow for lower costs and more flexibility in production while preserving the industry-leading features and quality Lex is known for.

Product Website: Lex Portable Distribution Boxes

Client: Lex Products, Shelton, CT

Product: 30 Amp Bento Box , Feed Thru

Product Type: Power Distribution Box

Target Markets: Entertainment, Commercial, Government

Creative Challenge:
Lex Products has a reputation for extremely rugged and well-designed power distribution boxes for military and commercial use. These products typically take power from portable generators via thick high-amperage cables and provide numerous outlets. The existing line of boxes were constructed with housings made of a rubber material that was expensive to process. Creative Engineering was tasked with coming up with a new approach to the design which would allow for lower costs and more flexibility in production while preserving the industry-leading features and quality Lex is known for.

Solutions:
Creative worked to develop a box based on a custom extrusion capped with overmolded end plates. The extrusion can be cut to length depending on the box requirements and incorporates “eyebrow” overhangs along the top edges to shed water. The end plates incorporate handles and stacking alignment features while also acting as feet to keep the unit off the ground. Overmolded elastomeric corner bumpers echo the rubber construction of legacy boxes and help protect the rugged build through heavy use.