The Product

The TD2100 is a pistol-grip wireless machine control in Eaton’s line of rugged handheld controllers for hydraulic equipment. It sits alongside the TD3100 belly pack in Eaton’s product family, sharing the same modular battery platform and the same mission: give operators reliable, responsive control over heavy machinery.

PDE contributed the industrial and mechanical design for the TD2100 as part of a broader campaign to unify and expand Eaton’s wireless controls lineup.

The Challenge

A Small Geometry Problem

The pistol-grip form factor is a natural fit for a handheld machine controller. Your hand wraps around the grip, your index finger sits on the trigger, and you’ve got a stable, comfortable hold on the device.

The catch is that the grip position puts the thumb at a fixed height. To hit the bottom row of buttons, an operator should be able to extend their thumb without breaking grip on the handle or shifting their trigger finger. For a device used over the course of a full shift, that’s the difference between a controller that disappears in the hand and one the operator is constantly aware of.

The design brief called for:

  • Full thumb reach across the button layout: operators should be able to hit every button, including the bottom row, without shifting their grip
  • IP67 sealing: the enclosure fully sealed against dust and water ingress
  • Modular battery compatibility: the TD2100 had to accept the same battery pack shared across Eaton’s updated product line
The Solution

A Recess in the Right Place

The solution was a recessed area worked into the housing around the handle. By pulling the enclosure geometry back in that zone, the thumb has room to travel further down the face of the controller without the hand needing to move. The operator keeps their grip and their trigger finger in position while their thumb can comfortably sweep the full button layout, bottom row included.

It’s the kind of detail that is easy to overlook in a render but immediately noticeable in the hand. The depth and contour of the recess balance thumb reach against structural integrity in the housing wall, producing geometry that feels natural rather than designed.

The TD2100 also received the updated battery interface to bring it into line with Eaton’s modular platform. The housing was updated to accept the new battery pack while maintaining the same IP67 sealing standard across the battery joint.

The Technologies Behind This Build

Mechanical Design
SolidWorks Injection Molding IP67 Sealing Ergonomic Form Development Modular Battery Integration