Product Engineering, Design & Development Case Studies

Driving Innovation in Tool Storage, Bit by Bit.

Sutton Stack-In is a modular drill bit and accessory storage system designed to offer unmatched flexibility, customisation and compatibility for trade professionals. This is a comprehensive solution consisting of Stack Racks, Stack Packs, Stack Tacs and Stack Tubs – each element designed to work seamlessly together and integrate with leading toolbox platforms.

Sutton was preparing to enter a new area of the market with this accessory storage project, so it was crucial to design a product with a point of difference and a high-impact shelf presence. Sutton approached Cobalt with a brief for a simple case and carry tote. Working closely with their team, this brief quickly evolved into a tool storage ecosystem flexible enough to accept Sutton’s entire product range.

Stack-In’s versatility simplifies manufacturing – cases for new and current product offerings can now be configured using existing parts and, if needed, by developing new bit racks. This saves on development and tooling costs while benefiting customers by providing freedom to organise their accessories as they wish.

Stack-In fills a key gap in the market for customisable bit storage. Hex shank drivers or drill bits slot into bespoke racks that clip into cases, which then dock into tubs for secure mobility, ensuring tools stay organised and accessible on site. A striking new design language elevates brand visibility and user-friendly features like clear windows, label areas, tether points and smart nesting enhance the user experience.

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Focus Areas

User-Centred Design
Industrial Design
Design for Manufacture & Assembly
CAD Modelling
Prototyping
Tooling Liaison and Management
Production Quality Control
Animation and Product Visualisation

Year

2024

Client

Sutton Tools

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Design Outcomes

Design Language

Robust Design

Manufacturing

User-centred Design

Product Range

Versatility

Stack-In introduces a bold new design language that reflects the strength and reliability of the Sutton brand. Clean lines, confident forms, and angular details complement the new logo – visually reinforcing the product’s quality, durability, and professional-grade performance.

A key challenge the development team conquered was creating a removable rack that locks securely into the case, while also providing reliable retention for the bits. Competitor products typically do one of these well, but not both.

Designed for smart, scalable manufacturing; built around common parts and interchangeable modules to reduce complexity and tooling cost. By aligning design with materials and processes, the system ensures reliable production, fewer defects, and a broad range of size options.

Stack-In was designed with tradies in mind. Every detail is considered to streamline setup, reduce frustration on-site and enable users to organise their kit as they see fit. With strong component connections, easy-to-carry handles, clear labelling areas and extensive mix-and-match capabilities.

Working with the manufacturer on design and DFM refinement, the design language was adapted to create a range of other products: Stack Tacs, bit boxes and the 33 pc case. These products widen the ecosystem and offer even more opportunities for users to make the most of Stack-In.

The Stack-In system is engineered for maximum versatility, featuring robust Stack Tubs with folding handles for compact storage, seamless integration with leading modular toolbox brands, and customisable configurations using Stack Packs, Stack Tacs, and Stack Racks to suit diverse trade needs.

The Team We believe that good design happens when experts work as a team.

Rachel Hook Project Leader

Chris Morrish Project Leader

Jack Magree

Justin Yuan

Graeme Marshall

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Beyond the physical product, Cobalt also helped bring the Stack-In story to life through animation. With hands-on knowledge of the design and its intent, our team created a short product animation that visually walks users through the system – showing how each part fits, stacks, and works together to create a cohesive whole.

Stack-In Animation Case Study