Notice Board
10 questions with HOPPE( UK) Product Engineer, Dan Savage
Dan Savage has worked as Product Engineer for HOPPE( UK) for seven years. His product design credentials span 25 years, having designed cordless vacuum cleaners as project leader at Gtech, as well as homewares for Next Home and washrooms for Venesta.
Tell us about about how you got into your career …
I hold a degree in Industrial Design from Teesside University, Middlesbrough. It’ s a hugely well-regarded course with many students going on to product design roles.
I’ ve always been passionate about blending art and engineering and was interested in drawing and sketching from a young age, as well as understanding how things worked. I studied art and design at both GCSE and A level.
At the same time, I was intrigued by engineering and being able to make things from scratch.
My dad was an engineer and owned a sheet metal business, so I got to know about processes and machinery at an early age.
What is your role at HOPPE( UK) and ARRONE, a HOPPE Group brand?
First and foremost, I look after product design and innovation. I design solutions to problems. This is a mix of new products and innovations to existing products, with a split of around 50 / 50.
I have big projects each year that we are looking at for marketplace entry, and design and deliver those. This incorporates innovation not only in design but also user experience, packaging and factory assembly. The ARRONE brand is strong and technically complex, and my work allows us to remain at the forefront of competitors.
I also control mechanical auditing with test houses to make sure CE and Certifire certification evidence is up to date and look after FPCs( production processes). I control the tooling register and handle new design inspection work, producing sample inspection reports( SIRs).
I deliver our PIM CAD drawings for catalogues and work with sales when they require the latest dimensioned drawings for customers.
What have been your big projects over the last twelve months?
My main focuses have been our new ARRONE AR227 Split Spindle for AR915 Apartment Locks, as well as PAS 24 panic hardware.
We needed a new split spindle to help overcome a problem of overtightening during installation. Split spindles have two halves that allow independent movement on each side of the lock. The door needs to lock securely from the outside, but offer quick egress on the inside, in case of a fire alarm, fire or need for escape.
My job has been about eliminating potential for assembly error. I have designed a solution to prevent overtightening with the clip-fix mechanism. It’ s going to make the fitting a lot faster so it’ s an exciting addition for us.
Tell us more about designing the split spindle …
Apartment blocks, hotels, or building with separate flats – typically anywhere where there are multiple doors in a building – require security so they can be locked from the outside and exited from the inside. This is done using a split spindle with a screw fixing.
To fit these, customers tend to use power tools. However, occasionally they are overtightened and this can mean the emergency side becomes more difficult to use.
Although the products contain full instructions it became clear we needed a better product to overcome this issue.
I designed a locking split spindle in two halves where part A is installed through the lock follower, and part B clips onto it with a sprung clip. It cannot be overtightened, it’ s five times quicker to install and uses less components.
This was the product of a eureka moment. I had the idea quite early on when I was looking at a luggage case with castor wheels. Some of them have wheels that can clip and unclip for storage and that give a reassuring‘ click’ sound when attached. I thought this could be used with doors, so it then became about developing and perfecting it.
The product has been tested and is available to purchase.
How would you summarise the favourite parts of your role?
It’ s all about making the user experience better and breathing new life into existing designs. The interplay of functionality and form across both residential and commercial is important to me.
Crucially, I design for the problem or to a cost, not necessarily for the sector or use. Design is also there to support the maintenance of a product – extending its use and lifespan rather than replacement.
The main job satisfaction comes when I arrive at a solution to a problem and have managed to really answer an issue end users have. I get great satisfaction from keeping customers happy.
What’ s your process for designing brand new products?
First, the team will get together and identify a set of products for design the following year. These will go through shortlisting where projects are prioritised.
18
MAY 2025
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