Mudgards: Branded, Heavy-Duty Ground Reinforcement Grid for the USA Market
A generic mud grid, rebuilt as a branded product
Our client, a USA company specializing in horse-related infrastructure and supplies, wanted to turn a generic ground reinforcement grid into a custom, branded solution for horse barns, training areas, and outdoor terrain.
The goal went beyond basic function: the grid needed to reflect the client’s brand identity and durability standards while staying interlocking, load-bearing, and cost-effective to mold at volume.
What made this project hard
Brand integration
A design language aligned with the client’s horse-focused brand, without weakening structural efficiency.
Snap-fit engineering
An interlocking mechanism that would not disengage under the weight of vehicles, trucks, and equipment.
Manufacturing at 700 to 800 grams
Large plastic parts needing a precise injection mold for consistent quality run after run.
Zero-undercut design
Keeping tooling cost-effective while integrating complex geometry and snap-fit features.
From generic grid to a heavy-duty branded product
Four stages, one team, no handoffs between them.
Concept Exploration
Over 50 grid pattern concepts explored, incorporating horse-inspired aesthetics.
Snap-Fit Prototyping
3D-printed prototypes validated the interlocking mechanism.
DFM for Molding
Zero-undercut geometry engineered for cost-effective tooling.
Production & Logistics
Heavy-duty mold run and DDP shipping to the USA managed end to end.
Over 50 concepts, one horse-inspired grid
More than 50 grid pattern concepts were explored, drawing on hoof impressions and organic symmetry to give the product a distinct, branded look.
Snap-fit prototypes tested under load
Multiple snap-fit prototypes were built and validated with 3D printing before committing to tooling, to confirm the interlock would hold under vehicle and equipment weight.
Zero-undercut design for cost-effective molding
The geometry was optimized for injection molding with a zero-undercut solution, keeping the mold cost-effective despite the complex interlocking features.
Heavy-duty production and DDP shipping
The mold was engineered for heavy-duty use and validated in its first trial. Large-scale production and container-level logistics, shipped DDP, delivered over 30,000 units to the USA.
What shipped
"A branded, heavy-duty injection molded solution, engineered for the USA market and delivered at container scale."
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