Sports Tech Startup
Full-Cycle Development Support
From a 5-person team to Series A funding. 8 months from concept to mass production, with on-site testing support in Italy.
Client Background
European Sports Tech Startup focusing on smart gear.
Timeline
8 Months (Concept to Mass Production)
The Challenge (2018)
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Team Scale
5-person startup team with no manufacturing experience.
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Product Positioning
Smart sports sensor device requiring installation on professional gear.
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Technical Hurdles
Extreme environment durability, miniaturized structural design, mass production process development.
Deep Technical Collaboration
Structure & Materials
- Snow Environment: -20°C to +10°C operation range
- Protection: IP67 Waterproof, UV resistant, abrasion resistant
- Material: PC+ABS Alloy + Glass Fiber for low-temp durability
Sensor Integration
- Protection: Withstand 100kg+ weight without damage
- Stability: Vibration damping & temperature compensation
- Yield Rate: Automated dispensing + visual inspection reached 98%
On-Site Testing
- Location: Italian Ski Resort (Winter 2021)
- Tests: -15°C performance, 60km/h impact, 8hr water immersion
- Iteration: 3-day turnaround for modified samples
Component Breakdown
Waterproof Housing
Ruggedized casing with custom red silicone seal for IP67 water resistance.
Mainboard Assembly
Compact PCBA fitting perfectly within the housing, managing sensor data and wireless transmission.
Precision Insert Molding
Macro view of brass threaded inserts molded directly into the plastic for superior pull-out strength.
Pressure Sensor Array
High-density sensor matrix layout for detailed foot pressure mapping.
Flexible Circuit
Multi-layer flexible printed circuit (FPC) designed to withstand repeated bending and impact.
Metal Stamping Parts
Assisted in prototyping and manufacturing of custom metal stamping components for the device assembly.
From Concept to Mass Production
Concept & Material Selection
Initial feasibility study and material sourcing.
3D Design & Rapid Prototyping
Iterative design process with 3D printed samples.
Mold Development
Tooling creation and trial shots (T1/T2).
Italy On-Site Testing
Real-world validation and design optimization.
Mass Production Validation
Process verification and first batch shipment.