Janzer Mailbox / Designer Series Mailbox

Marketing Needs

Janzer Architectural Corporation, a manufacturer of high end mailboxes, posts and signs, wanted a new flagship mailbox that would be superior to their competitor's in all aspects.

Engineering and Manufacturing Considerations
Early in the design of the product several manufacturing processes were identified that would provide the quality "feel" while allowing the minimum component costs:

• the posts, tops, and bottoms of the assembly would be extruded aluminum
• the door and back of the mailbox would be permanent-mold cast aluminum
• the support bracket and finial would be sand cast aluminum

The challenge was to make all of the components fit perfectly even though each manufacturing process entailed its own set of tolerances, advantages, and disadvantages.

Development Path

• create design concept sketches and renderings
• refine the appearance using customer feedback until consensus was achieved
• develop a 3-D model of the design including all aesthetic and assembly aspects.
• work with vendors to determine tolerance capabilities
• evaluate tolerance stack-ups to determine final part dimensions
• provide 2-D shop drawings to the various vendors
• evaluate customer provided prototype
• modify two small component designs that were not functioning as desired
• provide drafting and manufacturing support

The Result

The Federal Post-and-Mailbox is arguably the best in the world.  It is constructed of aluminum with powder-coat finish. Handle, front plate and address numbers are treated with a lifetime finish. It will endure the salt air of the coasts and extremes of the seasons in all regions of the country. The mailbox can be mounted to the left, right or front of the post.

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