Typically a rack skeleton is defined as an assembly of brass, steel or aluminum bars, including flight bar hooks, part contact clamps, shields and possibly current robbers. In some cases the rack will also include auxiliary or conforming anodes with the current fed through a separate circuit. The entire structure is Plastisol coated except for the flight bar hooks and contact clamps.

The challenges for building a good rack skeleton are manifold. First the rack has to be lightweight since the hoist system of a plating line can only lift a limited total weight (flight bar with one or multiple racks). On the other hand the rack has to withstand possible impacts without deforming and should transport the electrical current down to each contact clamp without excessive internal heat generation or ohmic losses. Finally, the dimensional accuracy for positioning the parts and active tooling components (shields, current robbers and auxiliary anodes) on the rack should be high enough in order to achieve optimal plating performance.

Elsyca starts from the parts configuration and tooling design as retained from a Computer Aided Engineering (CAE) project. Next the CAD of the rack skeleton is defined while accounting for the above mentioned targets and following any rules of good practice and constraints defined by the customer.

The deliverables to the customer are the CAD assembly of the rack skeleton, technical drawings of all components involved and the Bill of Materials (BoM) that specifies materials to be used for each component. Also the estimated rack weight with and without Plastisol layer is provided.

In co-operation with selected rack builders Elsyca also delivers prototype and even full production rack sets.

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