Automation Engineering Design Spotlight: Oncrux Rock Climbing Chalk
- Thomas A. Smith
- Sep 26
- 3 min read
What is Rock Climbing Chalk?
When it comes to climbing, grip is everything - and that’s where chalk comes in. Designed to absorb sweat and keep your hands dry, climbing chalk helps you maintain maximum friction on evInsert ery hold, giving you the confidence to push harder and climb higher. Whether you’re scaling an indoor wall or tackling outdoor mountains, chalk is a must-have for peak performance. From loose chalk and chalk balls to liquid formulas and solid blocks, there’s a type to suit every climber’s style. If you’re serious about climbing, chalk isn’t optional - it’s essential.
Who is Oncrux?
Oncrux is a Southern California based organization which features a team of dedicated climbers, lifters, and athletes who understand what it takes to push limits and perform at your best. They have developed a range of high-quality, performance-driven chalk products designed to meet the demands of any training environment. Recognizing an opportunity with overpriced and poor performing current chalk products, ONCRUX was created to offer a safer, more affordable solution backed by their experience in both cosmetics and athletics.
Issue with Packaging Throughput!
Being a small company that was experiencing increased product demand, Oncrux needed to improve their throughput on dispensing rock climbing chalk product into bags that are packaged and shipped to their distributors. Their current operation was very manual, involving the operator to pour the chalk into a tray and manually press the chalk through a funnel one bag at a time. In order to meet their increasing customer demand, the Oncrux team wanted to review a solution around automation engineering design. The goal was a semi-automated chalk filling system that prepared up to 80 bags at once was required.
Engineering Design Process
As with any engineering project, the first step is IDENTIFYING THE NEED. In this case, the need was clearly improving throughput to 80 bags per cycle. this would allow Oncrux to meet monthly demand for their chalk products.
The next step is to DEFINE THE PROBLEM, which involves understanding the key inputs and outputs, design requirements, and key characteristics of the materials involved. Working with Oncrux, we mapped out the current state process steps for this operation. This allowed us to identify which steps should be automated on this iteration and which would remain manual.
The next step is coming up with a CONCEPT DESIGN, which in this case there were several designs proposed. We looked a different chalk dispensing techniques (such as auger screws, vibratory feeders, and cell wheels), as well as manual versus automated plunger systems. The team ultimately determined that automating the chalk dispensing system would be tabled for the next design revision, automating the plunging action would be the focus, landing on a semi-automated system.
The next step is ANALYSIS AND OPTIMIZATION, where we developed a 3D CAD model, reviewed motion studies of the design, ensured the linear actuator selected was sized for the required force and velocity needed to achieve the cycle time requirement. A technical data package was created where a worst-case tolerance stack-up analysis was run, along with a design for assembly and cost analysis.
The next phase is EVALUATION where Oncrux and Dreamspace met and reviewed the design to ensure it met all requirements. Along with all the design requirements mentioned previously, another important requirement that was reviewed was ensuring cost was kept low and there was a focus to use off the shelf components. The majority of the build out uses off the shelf parts from Mcmaster-Carr and Progressive Automations. After the review the technical data package was submitted to Oncrux for the procurement and build of the system!
Conclusion
Overall this effort demonstrated great collaboration between an excellent client and the Dreamspace Engineering team. Throughout the process we kept in constant communication, working together to ensure we were aligned on the technical direction of the project. We used the latest version of Solidworks Design Software to generate the CAD files and technical data package, as well as industry standard engineering principles to size and select the proper materials for this design.
At Dreamspace Engineering we focus on product design, business capture engineering, manufacturing tooling, test equipment, technical documentation, and rapid prototyping providing the highest quality engineering service. Visit us at https://www.designwithdreamspace.com/request-a-quote to request a quote for service today!
Warmest Regards,
Thomas A. Smith
Owner at Dreamspace Engineering Consulting
P: 661-755-9225
Note: This is an original post created by Thomas Smith, not AI or any other chatbot.
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