AHERA: Connected Fitness Wearable

Ahera needed help on the mechanical and electronic design. The first prototype of the product & packaging was good enough to launch a crowdfunding campaign.
  • Examples of design improvements we provided: getting the motion sensor to work as expected (we also wrote the firmware); mechanical design for the magnet to fit and work nicely.
  • Time from design to functional prototype: 3 months.
  • Applicable certifications for selling in the USA: FCC, UN38.3
  • Tooling necessary for mass production: plastic injection molding for the casing, silicone molds
  • Critical components: display, casing, battery, PCBA.
  • Minimum order quantity in each color: 500pcs
  • Number of assembly workstations: 8 assembly + 2 testing
  • Highest sources of risks in assembly: waterproof feature and accelerometer calibration.

Alter RFS: Innovative filter system for cameras

After a successful Kickstarter campaign, this innovative product needed to be made by a capable and reliable manufacturer in China. We guided the founders Alter RFS to set up a solid supply chain, and at the same time we worked on technical solutions to reduce production quality risks.

alter-rfs
  • Examples of design improvements we provided: Improve magnet assembly for lowering the loss rate as magnet insertion as magnet is brittle.
  • Time from design to functional prototype: 3 months
  • Applicable certifications for selling in the USA: no
  • Tooling necessary for mass production: Aluminum extrusion mold
  • Critical components: CNC part with high precision
  • Minimum order quantity in each color: 100pcs
  • Number of assembly workstations: 10
  • Highest sources of risks in assembly: magnet assembly, and hinge tuning for ideal torque force

NAOX: Integrated sports cap & sunglasses

NAOX needed help with design, engineering including material selection, prototyping and production.
pink_cap-yelllow
  • Key challenges: Working with a large number of suppliers covering different fields (textiles, PVC, plastic injection, silicon, packaging, logistics…), designing reliable and effective system to hold the glasses.
  • Examples of design improvements we provided: The glass insertion system was developed and improved to meet comfort, cost, usability requested
  • Time from design to functional prototype: 8 months
  • Applicable certifications for selling in the EU & USA: FDA
  • Tooling necessary for mass production: plastic injection
  • Critical components: cap, sunglasses and insertion mechanism
  • Minimum order quantity in each color: 200pcs
  • Number of assembly workstations: 6
  • Highest sources of risks in assembly: glueing process of the nose pad on the glasses.

High end electronic cigarettes and vapes

This company had already made several models with Chinese manufacturers and needed to develop a more unique and complex design. Timelines were very tight and the client wanted to minimize the risks of IP leakage.
High end electronic cigarettes and vapes
  • Examples of design improvements we provided: quality improvements on plating (on aluminum casting), improved assembly process for fewer defects and higher efficiency.
  • Time from design to functional prototype: 4 months
  • Applicable certifications for selling in the USA: UL, FCC, FDA
  • Tooling necessary for mass production: testing jigs (functional, dimensional, HASS…)
  • Critical components: lithium polymer battery, cast metal alloy and PVD plating, PCBA and battery management system, borosilicate glass, heating ceramic
  • Minimum order quantity in each color: between 50 and 10,000 pcs
  • Number of assembly workstations: 35
  • Highest sources of risks in assembly: what cannot easily be tested or verified (e.g. pinched wires when closing the casing)

Sport massage accessories

This client had already spent a lot of time refining the design and qualifying the component suppliers, and yet he couldn't move fast enough on his own. We helped clarify his standard, check components quality, and set up a low-risk assembly process.

Sport massage accessories
  • Examples of design improvements we provided: none (there was already a very mature design from the client)
  • Time from design to functional prototype: 3 months
  • Applicable certifications for selling in the USA: none
  • Tooling necessary for mass production: assembly jigs
  • Critical components: hinges (must make no noise), foam, metal surface treatments
  • Minimum order quantity in each color: 1,000 pcs
  • Number of assembly workstations: 10
  • Highest sources of risks in assembly: ensuring hinge rotation remains within tolerances

Innovative pet cleaning products

This startup had a relatively immature design for a device that would clean pets in a novel manner. A lot of work was needed for picking the right motor and refining the design. Several rounds of prototypes were needed before zeroing in on the right design.
img-2
  • Examples of design improvements we provided: silent vacuum mechanism (500 watt motor) to avoid scaring pets, optimized airflow to cool the motor down
  • Time from design to functional prototype: 7 months
  • Applicable certifications for selling in the USA: UL, FCC
  • Tooling necessary for mass production: some assembly jigs, airflow test, pressure test
  • Critical components: motor, pump, PCBA
  • Minimum order quantity in each color: motor performance (heat, noise, flow)
  • Minimum order quantity in each color: 1,000 pcs
  • Number of assembly workstations: 15
  • Highest sources of risks in assembly: airflow sealings
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