Cubik Innovation make their debut at the Engineering Design Show at the Ricoh Arena in Coventry for an action packed 2-day event.
Cubik Innovation make their debut at the Engineering Design Show at the Ricoh Arena in Coventry for an action packed 2-day event.
The Reskube offers a simple solution providing access to both continuous power and uninterruptible internet connectivity for itself and any connected devices during a power outage.
With effect from 1 April 2023, Sam Beard will take over from Paul Mullen as Managing Director of Cubik Innovation.
This National Apprenticeship Week, we talk to Alicia about what motivated her decision to do a project management apprenticeship and the skills that she has learned along the way.
This National Apprenticeship week, we talk to Jake about his experience as a Production Apprentice, what he is studying and why an apprenticeship is a great way to start your career.
With the market struggling to settle, we explore what measures can be put in place to mitigate the effects of a changing landscape.
The global supply chain has become increasingly unstable causing component shortages across the industry. So, what does this mean for electronic components and when will we see an end to shortages?
This week, we had the pleasure of Ava Trewen's company as she joined the team for her Year 10 work experience placement. Find out what Ava got up to at Cubik HQ.
Kiwa are leaders in testing, inspection, certification and data services to a global customer base across a variety of market segments, including construction, utilities and public safety. Their hot swage joint analyser is used to measure the level of corrosion at the swage joint area of a streetlight column to determine its structural safety.
Kiwa approached Cubik for help with an existing product that was at risk of becoming unmanufacturable. Originally designed in the 1990’s, their hot swage joint analyser called for parts and components that had become obsolete since its inception.
Their objectives were to update the design to create a modern, handheld version and manufacture five new units, complete with full data pack including electronic design files and a software source file.
It was vital that the new design measured and calculated results in the same way as the existing device so that historic testing data could be inherited by the new instrument, without having to define new safety classifications.
The process began with reverse engineering the circuit and sourcing alternative components for the obsolete ones. We ran tests to understand how the device measured, inferring the method of operation and calculating results to fit those produced by the existing device. We then built a prototype breadboard version that allowed us to recreate the device’s operation and generate measurable results.
Using the output from our investigations, we created a custom PCB design and developed software to manage the system and record and present results via a digital display. Finally, we benchmarked the results against the existing device to ensure the results were consistent.
The hot swage joint analyser is one of the main tools used by Kiwa’s technicians to annually inspect and assess the structural integrity of over 130,000 lighting columns across the UK and Ireland, helping to ensure the safety of the public. As well as offering amore modern and functional aesthetic, the new design eliminates the immediate risk of obsolescence and creates a platform for further units to be built to support the scaling of the business.
Dr. Nick Gompertz created EarSwitch a wearable device that has the capability to change the lives of people with severe neurological conditions such as Motor Neuron Disease (MND). This in-ear innovation detects motion from one of the smallest muscles in the body, the tensor tympani, giving users the power to communicate and control their environment.
The Earswitch system comprises of an in-ear sensor and a processing unit that translates the information collected by the sensor and generates Bluetooth or USB data that is sent to the user's device. Nick and his team needed a multi-disciplinary team to help them develop their revolutionary device into a commercially viable product that satisfies strict medical regulations.
Throughout the project we worked collaboratively with several stakeholders including our colleagues in The Product Partnership. This enabled us to support Nick and the team from initial concept through to prototyping and into low volume manufacture for field trials.
For our part, we designed and developed a system architecture for the in-ear module and interface whilst keeping manufacturability in mind. The design was technically challenging and required miniaturisation of the in-ear module to ensure it fit the compact device, without compromising on quality and precision.
Once the device was ready, we assisted with regulatory approval including Electromagnetic Capability (EMC) and Medical Device Safety EN 60601-1.
EarSwitch is ground-breaking medical technology that will change the lives of people suffering with neurological impairments. It offers a transformational opportunity for people with the most severe communication restrictions to have a voice, take control of their environment and choose how to live their lives.
EarSwitch has been recognised innovative technology, winning numerous awards and securing significant investment.
Target Darts is a leader in darts equipment and sponsors some of the biggest names in the game including Luke Littler and Rob Cross. Their latest product creates a new category of connected IoT devices bringing the skill and excitement of the game to homes at the touch of a button.
The Virt Camera is a two-way camera system that allows users to play competitive darts against a global online community. It's front facing camera lets you opponent watch your throw, while the dartboard facing camera allows them to see your dart land in real time, high-definition video.
Target Darts approached Cubik with a prototype of their new product and asked us to conduct a design review that focussed on design for manufacture and supply. The Virt needed to stream two live video feeds to a remote server and an app that would configure and score the game. The biggest challenge was fitting the amount of tech needed into a sleek, compact design whilst maintaining a high-quality video feed.
As part of the design review, we produced a low volume build of the existing prototype to test and analyse. Using the output, we made design recommendations to improve performance and streamline the manufacturability of the product.
Getting the camera tech right was a big piece of the puzzle. Our team carried out extensive research and testing to select the best camera component. We then designed and built a bespoke PCB that enabled the camera to interact with off the shelf components to bring the whole system together.
With a refreshed design that employed design for manufacture principles, we went on to successfully support Target Darts through the regulatory certification process and achieved CE, UKCA and FCC approval.
The result, a market ready product that is now available to purchase: https://bit.ly/40fuW5k
The IZLID is a compact, lightweight infrared laser device used by the military as a command pointer for target marking and communicating with aircraft. It is small enough to fit into the user’s pocket, or attach to their belt for quick access, offering swift guidance to ground personnel over a range of 39km.
Close Air Solutions (CAS) asked Cubik to design a simulator that replicated the look and feel of the IZLID’s aesthetics, ergonomics and user functions, without the infrared beam. The IZLID simulator needed to connect to CAS simulation system via a single USB lead and return data back to the simulation system.
The IZLID simulator is used in classroom based military training to help soldiers gain knowledge and experience of how it would behave in a real-world application. Simulation is a critical part of military training allowing soldiers to experience realistic scenarios in a virtual world, improving their decision making and readiness for combat situations.
The Reskube offers a simple solution providing access to both continuous power and uninterruptible internet connectivity for itself and any connected devices during a power outage. It’s sleek and portable design means that it can be used in a wide range of settings from powering a home office to life saving medical equipment. This intelligent device has the capability to detect and resolve issues before they become a problem.
With our friends at Bang Creations delivering the mechanical design, we were brought on board to design and build the system architecture and support the product through regulatory certification. We worked closely with Bang to ensure the electronic system fit the custom enclosure without compromising on quality and performance.
Designed with critical remote workers in mind the Reskube gives users the confidence to work from any location without fear of disruption. Outside of the home, Reskube maintains continuous operations during outages for small sites such as retail stores, construction sites, doctor's surgeries, and primary schools, ensuring that critical systems and equipment remain operational. Additionally, it offers the added benefit of remote monitoring and management. In global regions where power outages are commonplace the Reskube offers a source of reliability and resilience in an environment with unpredictable connectivity.
Bristol & London based company, Switchee Ltd developed a smart thermostat solution aimed at reducing energy bills in social housing. The intelligent device learns the routine of the household, detects when the house is not occupied and turns the heating on or off accordingly. The device allows valuable data to be gathered remotely reducing the requirement for complex interaction or configuration from the user.
Switchee approached Cubik for help with the development of the software drivers which allow the operating system to communicate with the hardware. This quickly evolved into a larger scheme of work that incorporated the printed circuit board (PCB) design, prototype manufacture and firmware development.
Switchee is the first internet-connect device in social housing. It delivers real-time data that gives housing providers the insights and tools they need to proactively support residents and manage homes.
With a Switchee device installed, energy efficiency can be optimised on a case-by-case basis reducing energy waste, lowering heating bills and cutting carbon emissions.
Prototyping is a critical feature of any design process. When it comes to electronics there are many occasions when you might need a prototype, each with a different set of criteria, driving separate rationale. In this article, we explain what prototypes are and explore the different types that we use and what they are used for.
What is a prototype?
The Oxford English Dictionary defines Prototype as: “A first or preliminary version of a device or vehicle from which other forms are developed.”
Wiki describes prototype as: “A prototype is an early sample, model, or release of a product built to test a concept or process or to act as a thing to be replicated or learned from.”
We believe that both definitions are correct. A prototype is an early version of a product that is used to test a concept and forms part of the development process. However, it’s not a terribly useful definition as it essentially describes everything that we do from initial concept through to the product design is signed off and production-ready. We therefore use other terms to help describe what we are looking to do at different stages of the process.
Lash-up prototype
Early in a project we might be interested in testing a concept that has never been tested before. To do so, we need to get something working very quickly and at a low cost and time-spend. We call this type of prototype a lash-up. It is a one-off and is likely to be constructed on prototyping board such as stripboard or plugboard. If mechanical aspects are involved it might also include odds and ends from the junk lab.
Technology demonstrator prototype
A technology demonstrator is more advanced than a lash up and aims to showcase the main feature-set of a proposed product without fully resolving the product. To build it, we might use off the shelf parts such as development boards or opensource software modules but it’s unlikely that the electronics would be encased. The technology demonstrator is often larger than the final product. Some of the features will be omitted, for example, specific aesthetics or well-trodden aspects such as data posting to a cloud service.
Product prototype
This is a fully resolved version of the product with all, or nearly all, of the features included or attempted. It is aimed at the target market and is used to carry out field trials and collect detailed information about usability which is fed into the development prior to manufacture. The product prototype is likely to have the fit and form intended in the final product and is manufactured using similar techniques. If software is involved it might be a subset of the final version but the product prototype will be used to help develop that software over time.
What is not a prototype?
As we’ve discussed, a prototype is simply an early version of a product that is used to test a concept or theory. Essentially, it’s role is to determine if an idea ‘has legs’. Once that product is built to a specification, using predefined methods, tests and measurements, it is no longer a prototype, even if it is manufactured in very low volume.
Find out more about our flexible and comprehensive prototyping service.
Is additive manufacturing or 3D printing new technology? Not really. Paul Mullen (Managing Director) has been using this ‘new technology’ during product development since the 1990’s. In recent years, the cost point of the equipment has reduced to a level where it’s possible to have a 3D printer at home, but is this type of equipment suitable for commercial use?
Over the past 5 years or so, many hobbyist or semi-professional machines have come onto the market, mostly based on the Fused Deposition Modelling (FDM) process. FDM is a process where a filament of material (usually PLA) is extruded onto a plate in layers to build up the shape of the model being produced. This technology is great, its low cost to run and to own and often can result in great quality output but the final product often has limited use beyond the product development.
Five years ago, we purchased a Tier time UPBOX printer which uses this technology, and it has worked hard ever since, often being used to produce internal components, ‘looks like’ models and production test fixtures. The downside is strength and accuracy. We have also used this printer to produce parts on ABS so that we get the impression of an injection moulded enclosure. However, because of the manufacturing process, any prints always end up with striations, which is not great from an aesthetic viewpoint.
In our latest investment round, we have increased our 3D capability by adding in 2 machines – Stratasys Objet which uses a polyjet process and a Markforged Mark 2 which is a Continuous Filament Fabrication (CFF) process. These two additions offer a wealth of options for both prototyping and production due to their radically differing printing approaches.
The polyjet machine gives very high accuracy, repeatable, real-world parts which can be used in low volume manufacture straight from the printer. The Mark2 on the other hand offers the ability to produce carbon fibre or glass fibre reinforced parts which are great when traditionally you might design a metal, fabricated part. Parts using this technology are unbelievably strong and ideal for use in prototype applications.
To find out more about our capability, get in touch.
In January, we received an unusual enquiry through our website. Rather than an enquiry for product render, EMC consultancy or schematic design; it was a request from Mayor Marvin Rees asking to meet with our Managing Director, Paul Mullen, and all Cubik employees. He wanted to understand the work that we are doing and hear about our priorities and challenges. It was also an opportunity for the team to learn more about Marvin’s vision for the city and for our staff to speak with him about any topics, either directly related to their work or wider Bristol issues.
On the Thursday 28 February, Cubik Innovation hosted Mayor Rees for a whistle stop tour.
Paul and Sam sat down with Mayor Rees and Simon Cowley (Mayoral Policy Manager) to give introductions. Discussions then moved on to what the mayoral office could do to assist Cubik and other small businesses, in making business within Bristol, the UK, Europe and the world, easier and more viable. One concern raised by Cubik was the removal of small grants handed out to entrepreneurs and inventors, early in a product life cycle. After some discussion a potential route forward was proposed.
Mayor Rees was then given the opportunity to tour our facility and get hands on with some of our technology, followed by a Q&A with the team. The Bristol Mayor was questioned on everything from Bristol as a design and engineering hub of Europe, Brexit, the inner-city arena, gender equality in the workplace, paid parking at the workplace to commute transport within the city boundaries. The conversation was a fierce but fair one leaving most satisfied with the justification of the council actions as well as future plans.
This was a great opportunity for both parties to learn how decisions are made, whether it be at a local business level, or local council level. Ideas were exchanged, justifications for actions provided and it has led to an on-going discussion from both sides. From everyone at Cubik, thanks for your time, Mayor Rees and watch this space.
This month, we were joined by Joe for his week’s work experience. Here’s what Joe got up to during his time with the team:
Day 1
I started the day by sitting in on the Monday Morning Meeting where the team discusses each project and key priorities for the week ahead. It was interesting to hear about the different projects that Cubik work on. Afterwards I did lots of jobs and spoke with several people in the company. For example, I inspected plastics with Steve, found faults in PCB’s with Luke and also wrapped up some of the products in bubble wrap packaging. I also prepared wires and mechanically built products such as overcurrent boxes. At lunch, I socialised with some of the employees and gained an understanding of their role and responsibilities.
Day 2
Today, I gradually worked through and finished the 5 over current boxes with Mariusz giving instructions and help if needed. Throughout the day I was also given several other jobs, such as packaging and making tea, all of which help in some way. In the afternoon, Mariusz helped me develop my soldering skills which was very beneficial.
Day 3
I started the day with Mariusz, polishing and wrapping the 5 over current boxes ready to be shipped, which took a considerable amount of time. After lunch I prepared a bunch of wires and cables by cutting them precisely, and some for the sleeves, which again took sometime. I also put serial code stickers on located areas on PCB’s - which is not as easy as it sounds.
Day 4
Today I was heavily involved in the structuring process of PCB’s and cables, with Steve and James, who work in the production team. I had to delicately place wires into slots and screw them in, in the correct order, without breaking them which was quite a fiddly job. I also helped Mariusz organise scrap materials and tidy the workshop.
Day 5
On my last day, I finished the Wessex Hatches wrapped them and put them in a box with a cable. I then wrapped and prepared them for shipping. Later in the day I observed Luke whilst he tested several PCB’s in different ways. I then precision cut 80 wires to 280mm long using a technique Mariusz had taught me. Finally, I helped wrap some more mechanical and metal products.
This month, we were joined by Harry for his week’s work experience. Here’s what Harry got up to during his time with the team:
Day one
Today I worked in Production and the Metryx production room, learning how things are done. First, I was shown how to check that everything ordered had arrived and that the quantity of it is right. Then I did some mechanical work on WES001P. Finally, I cut wires to the correct length and then stripped and crimped them with Mariusz in the Metryx production room.
Day two
Today, I was back with production. I started by checking a few deliveries against the delivery notes to ensure they were the correct components ordered. I then moved from the production room into the Metryx room and helped Josh QC/QA check 4 fan units by checking the wiring for continuity and checking all the clipped in parts were clipped in. We also checked that the screw torque lines were correct and lined up. After all these passed, we wrapped 2 fan units using bubble wrap and Sellotape and boxed the other 2 to ensure safe packaging. I then returned to the production room and wired all the WES001P that I had put together the day before. Finally, I helped Luke package the LIM chargers by bagging all the accessories and boxing them.
Day three
Today I have been working in the design team with Russell. I have been learning how to use Solid Works 2018 and can now design simple things like a ninja star. I have been listening and working along to tutorials on Solid Professor. Before I came here, I only knew the very basic concepts on SolidWorks but now I can design and evaluate designs. After I learned how to use SolidWorks, I was told I would have a chance to design something which I could 3D print - a ninja star. After I had designed the ninja star, and had the design approved by Russell, he took me to the 3D printing room where we started to print it. As it was getting late in the day, and the print would take 2 hours and 40 minutes, I wasn’t able to collect it until the following day. There were a few problems with the 3D printer initially. The pad which the filament is laid onto didn’t heat up properly meaning the filament wouldn’t stick. We turned the machine fully off and back on again which solved the problem. The filament didn’t seem to stick to the bed the first couple of tries but eventually it did and then ran smoothly from there.
Day four
Today I inspected my 3D printed ninja star which had printed without fault. I then worked in production for the day where I mainly checked deliveries against their dispatch notes to ensure that they were the correct component and have arrived in the correct quantity. I then did some mechanical work putting Pitchmark fuse boxes together. After that, I booked in all the components which had arrived by checking they’re quantity and order numbers. Once completed, I kitted for the job by putting the specific components in all the boxes ready for hand assembly.
Day five
On my last day, I worked with Marijan, and we produced a schematic and a circuit. This was a circuit that takes solar energy and transfers it into spinning an uplift (which is a piece of art). The circuit which was already made looked messy and didn’t make the most of the solar energy meaning the uplift wasn’t spinning to the speed it should be. It also didn’t spin as smoothly as expected. We redesigned the circuit on Altium designer so that it worked smoothly and quickly. We printed off the finished designs ready for approval so they can be sent off and the boards printed to enable volume production to start.
On 27 September, we attended the Business Leader Awards held at Ashton Gate as nominees for Business in the Community, against some tough competition including Bristol Sport and Andrews Property Group.
The evening started with a champagne reception followed by a formal three course dinner. Once service had finished, comedian Russell Kane took to the stage to entertain the crowd. During his act, he took a particular shine to our very own Camilla.
Unfortunately, we didn’t win our category, but it was an honour to have been nominated amongst some of the best businesses in the region.
We had a fantastic evening from start to end. Not only did we love getting glammed up but also the opportunity to network with some fantastic companies and individuals.
On Sunday 22 April, Cleve RFC competed in the ‘Gloucester County Under 16s Plate’ final against Hucclecote RFC. As one of the main sponsors of the age group we are proud to report that following an exciting match, the Cleve boys came out on top in a 43-22 win.
With creative touches of brilliance mixing with well-constructed set plays coming from both teams, it was clear that the boys were delivering a high level of rugby and both teams deserved to be in the final.
In the first half, both teams suffered injuries with the 3G surface and intense competition taking its toll. However, there was depth of quality throughout the rival squad and the players didn’t let injuries stop what was a great contest.
After a very nervy first half ending 12-17 to Hucclecote, the supporters on the side line didn’t stop believing in the Cleve boys and their encouragement inspired the lads for a outstanding second half performance.
With an early try to Cleve the momentum had shifted and there was an increasing belief, after the loss in the same final last year, that this year the boys would walk away as champions.
The final play resulted in Cleve scoring another well worked team try and as the final whistle came, the boys ran to a huddle to begin celebrating what was a great win against a tough and capable Hucclecote team.
This final game of junior rugby was the icing on the cake for what has been a fantastic journey; from under 7s rugby through to development and senior rugby next year. As the club moto says: ‘we sow to reap’.
A massive thank you to the coaches who dedicated their time over the past ten years; a job well done.
We’re getting in the festive spirit at Cubik HQ, and to spread the festive cheer, we have designed a LED game that doubles up as both a Christmas card and tree decoration.
We followed the same 5-phase gate system for this seasonal project that we do for most of our customer projects:
Specification
Following the success of our previous Christmas cards, this year’s innovation was to design a snowflake PCB with an increased number of LED’s, increased number of gaming levels and infinite lives.
Design
The snowflake PCB schematics were designed in Altium Designer and reviewed internally using our typical internal review process.
Production Prototype
The blank PCB’s and electronic components were procured, which allowed for PCB assembly to begin.
Software
Based on the previous firmware we developed the sequencing of the LED’s, increasing the number of levels and game completion animations.
Test
Internal testing involved Cubik team members attempting to complete the game and assessing whether the product worked as it should.
Matt Jackson, one of Cubik’s Senior Software Engineers explains how he approached the Software Phase of this project:
“As this year’s Christmas card is an evolution of the last, we started with the previous firmware as a starting point. The snowflake design has a greater number of game LEDs, and they are laid out differently on the boar, so the first challenge was to change the sequence of LEDs to fit the new layout. Next, we added more levels and gave the player infinite live. It is Christmas, after all!
Each level has a unique speed or pattern which needs tweaking to keep it interesting from one level to the next. At this point everyone in the office had a play so we could evaluate the difficulty. After a couple of iterations to refine the patterns and difficulty, all that was left was to make some pretty animations for winning the game and sitting on your Christmas tree.”
After months of hard work and Standard Operating Procedures (SOPs),we have passed our ISO audit which means we are ISO 9001:2015 certified. This is the international standard that specifies requirements for a quality management system (QMS). ISO 9001 is the world’s most widely recognised quality management system accreditation and monitors quality across our business, benchmarking consistent performance and service with the goal to enhance customer satisfaction.
Sam Beard, Operations Manager and ISO lead said:
“As a company we are delighted that all our hard work has paid off. The standard itself shows a commitment to continuously improving business processes. This not only benefits Cubik, but also enforces major improvements to our customer interaction and working; ensuring they have a pain free journey with Cubik and receive the best achievable output from a project.”
ISO 9001 is based on the 'plan do check act' methodology and provides a process-oriented approach to documenting and reviewing the structure, responsibilities, and procedures required to achieve effective quality management within an organisation. Specific sections of the standard contain information on topics such as:
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