When people talk about EV charging solutions, the focus is usually on the charger itself, its power output and control software. In a real installation project, however, the result is also significantly influenced by the charger post, mounting plates, cable routing, the placement of electrical components and access for maintenance.
Modurex Systems approached Revismo with the goal of developing a universal and scalable installation solution that would make EV charger installation simpler and faster. The brief was not to design a single metal post for one specific charger, but to create a product system based on a common structure that could be adapted to different chargers and installation scenarios.
Universal does not mean one solution that fits everything
The word “universal” is often used in product development, but in practice it can mean two very different things.
One option is to create a system with as many mounting points and adjustment possibilities as possible, so that it should theoretically work with a wide range of products. In practice, however, such a solution can become difficult to manufacture, inconvenient to install and visually unattractive.
The other option is to create a product platform in which the main structure remains largely unchanged while different interfaces are handled through interchangeable or add-on modules. For the Modurex charger posts, this meant developing a common charger post structure together with charger-specific adapter plates and accessories.
This architecture makes it possible to add new charger models to the system without redesigning the entire charger post. When a new charger enters the market, the main development task is to create the appropriate interface component rather than starting the whole product development process from scratch.
A good product also considers the installer’s workflow
The user of a charger post is not only the person who will later charge their vehicle. The product’s first user is often the installer, who needs to transport, anchor, cable and later maintain the charger post.
The development process is therefore considered, among other things:
- cable routing to and inside the charger post;
- the installation sequence of the charger;
- access to connections and fasteners;
- the possibility of installing one or multiple chargers;
- placement of electrical components and DIN rails;
- integration of sockets, cable holders and other accessories;
- manufacturability and ease of assembly.
Installation time is part of the true cost of the solution. Savings achieved in manufacturing do not necessarily translate into an economic benefit if the design makes installation more difficult and increases the amount of work required on site.
One of the strengths of the Modurex team was its clear understanding of both end-user and installer needs. The company did not treat the charger post simply as a structural component, but as part of the complete charging solution. Regular technical feedback made it possible to evaluate concepts based on practical installation needs rather than appearance alone.
From concept to production-ready documentation
Revismo’s work began with developing the product concept and the logic of the modular system. Industrial design and mechanical engineering progressed in parallel because, in a product like this, external form, manufacturing technology, component layout and usability directly influence one another.
Once the concept had been approved, a detailed CAD model was created, including manufactured parts, purchased components and fasteners. This was followed by production drawings, a bill of materials and components, as well as operating and installation instructions. The project also included mapping the applicable European Union requirements.
Production drawings and a bill of materials are not merely documents needed to manufacture the first prototype. Well-structured manufacturing information provides the foundation for repeat production, costing, quality control and future product modifications.
One charger post developed into a complete product range
The Modurex solution reached the market as two main charger post models complemented by a range of modules. Core Basic and Core Pro Rail use the same basic form but are designed for installations with different levels of complexity.
Today, the Modurex range includes more than 10 products. In addition to the two charger posts, the system includes adapter plates for different chargers, a cable holder, post extension, socket plate, ground installation base and base cover. Onninen currently lists 11 Modurex products, including the Basic and Pro Rail charger posts as well as several adapters and accessories.
This demonstrates the practical value of modular product development. Instead of one large product containing everything, the result is a system that can be configured for the requirements of a specific installation. At the same time, the manufacturer can expand the range with new modules while retaining much of the existing structure, manufacturing tooling and documentation.
What can we learn from this project?
The Modurex project showed that a successful product platform does not begin with trying to include as many functions as possible. Universality works best when the parts of the product that can remain common are standardized, while the parts that need to adapt to the charger, installation site or use case remain configurable.
It is equally important to consider the product across its entire lifecycle. In addition to appearance and technical performance, the development process should consider manufacturing, assembly, transport, installation, maintenance, documentation and the ability to develop the product further in the future.
Modurex’s practical input and clear understanding of market needs, combined with Revismo’s expertise in industrial design, product development and CE compliance, made it possible to turn the original idea into a complete product system. This reflects Revismo’s broader approach of combining engineering, compliance and documentation throughout the product development process.
Modurex charger posts and accessories are available from Onninen: View the Modurex product range on Onninen