Enterprise data centers rely on high-performance storage arrays to manage and protect critical data worldwide. In these high-density environments, visual status signaling directly on the chassis helps system administrators monitor equipment health and quickly identify active arrays.

Pure Storage, an enterprise flash data storage provider, needed to integrate an illuminated logo badge onto the front of its storage chassis. Beyond displaying brand identity, the badge had to double as an active indicator, communicating real-time status messages without modifying the existing chassis design.

Flash memory is widely used in applications ranging from smartphones and digital cameras to scientific and medical instruments. No matter the industry, the safe and secure storage of company data is a top priority for organizations worldwide.

To support this mission-critical hardware, the illuminated logo badge needed to function as a multi-color status display, projecting bright, uniform light through a compact footprint to communicate clear operational messages to end-users.

While the request may seem simple at first glance, the physical design of the front panel posed a unique set of engineering challenges:

• Perforated Panel Pattern: The chassis front panel was constructed from perforated metal with an intricate design, providing very limited surface area for mounting the badge.

• Fixed Mechanical Layout: The original chassis design could not be altered, ruling out structural re-tooling to accommodate the badge. Our engineering team collaborated closely to brainstorm custom solutions within these strict mechanical limits.

• Power Constraints: Electrical power availability within the primary chassis layout was constrained, requiring an alternative power connection strategy.

Our value-added services team collaborated closely with Pure Storage to overcome their mechanical and power constraints without altering the primary chassis:

• Photometric Simulation: We leveraged a combination of CAD technology and advanced light modeling tools to run simulations on photometric and illumination properties, developing a solution that delivered optimal light to the original assembly design.

• USB-Powered Module: Due to limited power availability in the chassis layout, we developed a custom LED module that connected directly to a nearby USB port for power. Our team ensured the light pipe was positioned precisely with the USB power supply to deliver ideal illumination at all viewing angles.

• Rapid Prototyping and Tooling: We used Stereolithography (SLA) and Fused Deposition Modeling (FDM) technology to rapidly prototype and test our solution. Once it passed rigorous testing, we tooled the production solution using plastic injection molding, which significantly improved assembly efficiency and reduced manufacturing costs.