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Manufacturers of durables and capital equipment frequently seek to extend the life or increase the sales of a product by finding new uses or applications for it. While this may make commercial sense, it is a practice which may have its dangers. This case study, with its technical or engineering background, highlights some of the problems in (i) analysis of the new product function and its operating environment, (ii) engineering design and materials performance, (iii) communication between design, material procurement and production staff, and (iv) monitoring and quality control procedures. Lessons in these and other aspects of design management can be drawn.