Client: Wink Solutions
Services: Mechanical Design, CAD Modelling, Design for Manufacturability
Industry: Public Health Technology

During the peak of the COVID-19 pandemic, the risk of virus transmission through physical currency emerged as a significant public health concern. Wink Solutions identified a critical gap: the need for a reliable, rapid, and non-destructive way to sanitise both banknotes and coins. Their vision led to the development of a currency sanitiser machine, an innovative device designed to disinfect circulated currency in high-traffic environments such as banks, retail stores, and transport hubs.

Applied Project (formerly operating under AUSK) was engaged to provide full mechanical engineering design support. Our team delivered CAD development, prototyping coordination, and design-for-manufacture (DFM) refinement. The project gained notable media attention, including a televised interview with founding partner David Gardner, highlighting the machine’s relevance and potential impact.

The Challenge

Designing a machine capable of sanitising two fundamentally different types of currency—fragile paper notes and durable metal coins—required a sophisticated and reliable mechanical approach. Key engineering challenges included:

• Gentle handling of paper notes without causing tearing or deformation.

• Robust sanitisation of coins, which required higher thermal and mechanical tolerance.

• Ensuring complete UV and heat exposure while protecting the structural integrity of the currency.

• Delivering a compact, user-friendly form factor suitable for public deployment.

• Preparing the design for scalable manufacturing during a global supply-chain crisis.

Our Approach

Concept Development & CAD Engineering

Using Autodesk Inventor, our team developed detailed 3D models and functional simulations to validate mechanical operations early in the process. Iterative modelling allowed us to optimise component layout, internal flow paths, and serviceability features.

Prototyping & Refinement

We partnered with an external prototyping provider to build physical test units. These early prototypes acted as essential validation tools, enabling us to:

• Identify performance and handling issues

• Refine UV and heat chamber geometry

• Calibrate mechanical tolerances

• Improve user interaction features

Feedback loops between testing, client review, and engineering analysis ensured rapid, informed design iterations.

Mechanical Design for Manufacturability

Applied Project’s primary responsibility was refining the mechanical system for manufacturing at scale—excluding electronics. Our DFM enhancements included:

• A dual-path currency system:

  • Note Path: Soft-roller feed system with controlled UV exposure

  • Coin Path: Heat-assisted tumbling mechanism

• Optimised sanitisation chamber layout for maximum UV/heat efficiency

• Material selection focused on durability, hygiene, and ease of maintenance

• Modular internal architecture to simplify servicing and reduce operational downtime

• Reduction of part count and introduction of manufacturing-friendly geometries

These refinements significantly improved reliability, cost-efficiency, and production readiness.

Project Outcomes

The final currency sanitiser machine delivered:

• Reliable sanitisation of both notes and coins

• Compact deployment footprint with intuitive user operation

• High mechanical durability for public-use environments

• Enhanced manufacturability, reducing production cost and complexity

• Strong public/media interest, reinforcing the machine’s relevance

An Australian news network featured the project, where David Gardner highlighted the machine’s role in supporting safer handling of physical currency during the pandemic. This coverage reinforced the innovation’s value and the engineering behind it.

Applied Project’s work with Wink Solutions demonstrates our capability to rapidly develop and refine mechanical systems in response to global challenges. By combining strong CAD engineering, practical prototyping insights, and manufacturability expertise, we helped transform an urgent public-health concept into a commercially viable, real-world solution.

This project remains a standout example of our commitment to precision, innovation, and impactful engineering design.