When developing electronics there are many reasons why you might need a prototype. We explain what prototypes are and explore the different types that we use and what they are used for.
When developing electronics there are many reasons why you might need a prototype. We explain what prototypes are and explore the different types that we use and what they are used for.
As the cost of 3D printers comes down making it more accessible to have printers in homes, we explore whether this type of equipment is suitable for commercial use.
Recently, we were joined by Mayor of Bristol, Marvin Rees who was keen to learn more about what we do and understand the challenges that we face.
Recently, we were joined by Joe for a week's work experience. Find out what he got up to during his time at Cubik HQ.
Recently, we were joined by Harry for a week's work experience. Find out what he got up to during his time at Cubik HQ.
We were delighted to attend the Business Leader Awards at Ashton Gate as nominees for the Business in the Community Award.
Cleve RFC compete in the Gloucester County Under 16s Plate final. As official sponsors, our team were pitch side to cheer the boys on in what was an exciting match.
To spread some festive cheer, we've developed an LED game that doubles up as a business card and game. Find out how we designed and developed it.
We are delighted to announce that we have passed ISO 9001:2015, showcasing our commitment to the continual improvement of our business processes.
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.
Are you interested in reshoring your electronics manufacture but need to keep manufacturing costs in check?
Recently we have seen several companies move their electronics manufacture back to the UK. As we covered in our previous article, some products lend themselves to UK manufacture. But some techniques that are often applied abroad do not work in the UK due to labour cost.
One example is the good-old soldered wire. In China, for example, it is quite common to solder a flexible wire directly to a PCB and is usually carried out by hand. Manual operations like this are obviously possible in the UK but are often not cost effective. Adding a simple wire to PCB connector could reduce the assembly cost because the connector is machine assembled, rather than hand assembled, and the reduction in labour time offsets the additional parts cost
In “low-cost” countries, the Bill of Materials (BoM) is scrutinised during manufacture cost-down and, where possible, is cost reduced. This is often achieved by removing parts such as wire to board connectors and replacing them with direct soldered connections. For UK manufacture, a different approach must be taken.
One method that Cubik has used successfully is to add separate, costed lines to the BoM for machine time and labour time (often called touch time), per process step. By organising the BoM by cost and reducing the most expensive lines we are forced to review the manual processes which will likely lead to a reduction in touch-time. Adding connectors into the BoM can then be considered based on cost.
In addition, a design iteration focussed on optimising the product design for UK manufacture should not be ruled out. Design fees can be expensive, and you may also need some additional compliance testing, but this cost could be offset against the unit price benefit. There may also be an opportunity to fix any other issues at the same time.
So, to reduce costs in the UK:
Whilst there are sometimes benefits to sending electronic products abroad to be manufactured, evolving methodologies in the UK, together with the key advantages of keeping your product close to home, means that UK manufacture is a viable alternative.
Over the past 3 years we have seen several companies move their electronics manufacture from the Far East and other “low-cost” countries, back to the UK. Surely this cannot be competitive, can it?
We recently carried out a cost comparison on a batch build of 2000 assemblies. Our UK cost was around 25% higher than that obtained from a Chinese partner, excluding import duty. That is quite a difference, isn’t it? So, why are some companies looking to build in the UK rather than exporting manufacture to another country?
After speaking to customers who have reshored their electronics production, the reasons are clear:
It is difficult to find an overseas manufacturer who is interested in producing less than 5000 units.
Customers that have returned their manufacture to the UK have seen many benefits which can offset the lift in unit price. It is these benefits that are leveraging the return to UK manufacture. It is true, there are some products that do not lend themselves to manufacture in the UK. Low cost, high volume consumer products can be difficult to manufacture competitively in the West, but many products do not sit in this category. Industrial and professional electronics are less cost sensitive, are generally produced in lower volume and are great candidates for UK manufacture.
So, what are the benefits of manufacturing locally?
There are a few tricks that can be applied to reduce the cost of assemblies in the UK. We will look at these in more detail in our next article.
Since 1985, manufacturers have been required to affix a CE mark to certain products to allow them to be sold in the UK and Europe. In the electronics industry, this process is well trodden as almost every product needs to be CE marked. But what happens on New Years Day 2021 when we wake up and are no longer part of the European Union (EU)?
From January 2022, manufacturers of all applicable products sold in Britain must affix the new UK Conformity Assessed (UKCA) mark.
If the product is going to be sold in the EU and Ireland the CE mark must also be used meaning most products will be marked with both marks.
Manufacturers will be given a transition period to allow them to evaluate their products requirements, obtain the appropriate documentation and make the necessary changes. From January 2021, they will be able to use either the CE mark or the UKCA mark. From January 2022 the CE mark will no longer be recognised in Great Britain and, by January 2023, the UKCA mark only must be affixed directly to the product.
So, what does this mean for my product?
If your product was tested to the British standards you may not need to retest it, but you will need to generate a UKCA declaration and amend the technical file. Information about the standards to which your product has been tested should be stated on the Declaration of Conformity. If your product was tested to the International version of the standards it is likely that some additional testing may be required.
Cubik Innovation have extensive experience in the field of product compliance testing and documentation. Alongside our network of partners, we are well placed to help transition to the new legislative requirements. If you need help to ensure your product meets the new standards, get in touch.
We are delighted to announce that Ian Binder has joined the Cubik team as Business Development Manager.
Ian brings with him over 30 years’ experience in the engineering sector and has previously worked for several engineering firms, in both technical and commercial roles.
He joins us from Kinneir Dufort where he worked as a Principle Project Manager and, most recently, Head of Industrial and Defence Sector.
Prior to that, Ian began his career as a draughtsman where he trained as a design engineer before securing his first role at Huggett Electrical in Bath in the HVAC control panel industry. After 7 years, Ian moved to Stentorfield in Chippenham where he was responsible for the development of vending machines. When Stentorfield were taken over by vending machine manufacturer, Crane, Ian progressed to the role of Engineering Manager where he spent the next 15 years.
Speaking about his new role, Ian said:
“Cubik already do excellent work and have built up an exceptional reputation. My objective is to find areas of the business where I can add value, develop our offering and, ultimately, help the business grow. I am here to better understand our client’s business needs and ensure client focus throughout the development process.”
Since Cubik was established in 2012, this is the first time the business has appointed a Business Development Manager. Managing Director of Cubik, Paul Mullen, speaks about what Ian will bring to the team, to the business and why now is the right time:
“Ian comes with a wealth of knowledge and experience in product design, engineering, and project management. There is a definite upturn in our sector so growing the team in all areas to accommodate additional work is a logical progression. Ian will help us promote our skills, develop new connections, and produce more. I am delighted to welcome Ian to the team”.
The process of taking any new product to market can seem long and daunting. Add electronics, software, or hardware into the mix where the scope for complexity increases and it might just be enough to put any one off trying all together.
Whether it is an idea on the back of a beer mat after a conversation between friends at the pub or a global corporation with a fully developed idea, Cubik Innovation has the experience and technical expertise to support our customers at every stage of the process. Here we offer a brief overview of each stage of our process from concept right the way through to production.
Initial Concept
So, you’ve got a great idea for a product but now you need to flesh out your idea and develop the concept. Think about, what you want the product to do, who will use the final product and who the target market is. If you know how you want it to look, you can create sketches of your idea and make notes on how you think it will work.
Product Specification
This is where we get into the nitty gritty of what your product can do, clarify the scope of the project, desired timelines, and key priorities. By now, you should have an in-depth knowledge of the product you want to create, the need it solves and the desired functionality. Does your product solve a real-life problem? Are there any products on the market like yours? How can you improve on what is already on the market?
At the end of this phase, you will have a Technical Design Specification (TDS) that details the system architecture and outlines all the technical requirements that need to be met. This will form the blueprint from which your product will be developed.
Design
The design phase can be broken down into 3 stages: electronic design, printed circuit board (PCB) design and mechanical design.
Electronic Design: Our engineers use their technical knowledge and experience to select the best components needed to achieve the desired functionality and usability whilst keeping within budget constraints. When selecting components, there are various factors that need to be considered which will impact what materials are selected to ensure the product runs safely and at full capacity. Taking time to think about what is required will help guide future decision making and ensure the best chance of achieving the final design. Once selected, we produce a schematic design which depicts the graphical representation of the electrical circuit and its components.
Printed Circuit Board Design: Using layout software, the printed circuit board (PCB) design process takes the schematic design and brings the electronic circuit to life in a physical form. This process combines component placement and routing to determine a map of electrical connectivity.
Mechanical Design: Once we have finalised what is electrically required to make your product function, we begin to design the components, or systems of a mechanical nature. Here we consider what is mechanically required to obtain a useful output i.e. to make your product work. For example, the enclosure or housing, buttons, switches, and bearings all fall under the scope of mechanical design.
Using Solidworks software to produce a computer aided design (CAD), we create a detailed technical drawing of your product and the physical components that have been selected.
Software
Incorporating specific software code can increase the level of functionality of the PCB and, ultimately, the product. This phase often poses a dilemma where we must determine if the desired outcome can be better achieved through specific software code or hardware circuitry. So, it is important to balance the advantages and disadvantages of either approach.
Prototyping
Once the product design has been finalised we can begin working on a prototype. The type of prototype that is developed will depend on the product and the intended functionality and may, or may not, contain all the products features. You can find out more about the different types of prototypes in our article: Prototyping – What is it and do I need it?
Prototyping is a critical phase in the design process. It allows us to evaluate the overall product concept as well as validate our ideas and design assumptions. It also gives us an opportunity to explore the mechanical features so that we can ensure the best selection of parts and components.
Testing
Another critical part of the process is testing as it gives us an opportunity to identify any potential problems or flaws in the products design. By carrying out tests early in the process, we can resolve any issues and find alternative solutions ahead of compliance testing, saving both time spent and budget.
During the design phases special consideration is given to the types of tests that are required and how those tests might be completed in both the prototype stages and during batch manufacture. For example, we may add test points to the PCB to enable a bed of nails automated test rig to be used.
During the design and initial testing phase the engineers will methodically work through the design, testing and verifying the various parts of the system, one at a time. Items such as power rails will be brought up independently to ensure they are functioning correctly before running the system in its entirety. This ensures that no damage is caused to the PCB and that we can rectify any issues before they cause any knock-on effects.
Iterative Design
This is a cyclical process of prototyping, testing, analysing and refining the product. The aim of the process is to get closer to the solution with each repetition of the cycle. Using the results from the latest round of tests, we adjust and refine the product to ensure that it meets the technical requirements that were set out during the specification phase.
Compliance Directives & Standards
To ensure the safety of the end user all electrical products are subjected to thorough and vigorous compliance testing. The scope of directives and safety standards is vast and the electronic and mechanical make up of the product will dictate which compliance directives and standards need to be met.
Another consideration is whether you plan to launch your product abroad as regulations may vary between countries and you may be required to meet different or additional directives.
To ensure the best chance of passing compliance testing first time, we design all products and make suitable component selections with compliance testing and manufacture in mind.
Manufacture
The final stage of the design process is manufacture during which the tested a validated product is manufactured on either a large- or small-scale basis.
The first step in this process is to generate the necessary files needed to produce the product. These would typically include, PCB files or Gerber’s, a Bill of Materials (BOM), assembly and test instructions and any additional files such as mechanical design files.
These files are verified by the Production Team to ensure they contain the required information, in the correct format. The job is then loaded into the Production schedule.
PCB blanks and components are ordered from our trusted partners and any tooling that is required such as a paste stencil is also ordered. Once these items have arrived the files and components are loaded onto the pick and place machine(s) and the engineers will run a batch of PCBs through the semi-automated production process, including stencil printing, placement, reflow and inspection.
Once the PCBs have been produced and have passed inspection the boards as tested using the test procedure provided. They are then assembled into an enclosure, mechanical assembly or boxed with their cables and instructions leaflets as required. All items are then put through quality control before being packed and shipped.
Over the course of the following expert articles, we will explore each of these phases in technical detail including what is expected during each phase, how key decisions and selections are made, and the intended output at the end of each phase.
Cubik Innovation are delighted to announce the promotion of not one but two members of our team. Camilla Saunders has been promoted from Finance Manager to Business Manager. As well as continuing with her usual finance and HR duties, Camilla is now responsible for managing the Business Team which includes Admin, Project Management and Marketing.
Phil Potter makes the move from Principle Design Engineer to Design Manager and is now responsible for the management of our Design Team.
Speaking about the change in Cubik’s team structure, Sam Beard (Operations Director) said:
“Having Camilla and Phil join Steve (Production Manager) as department managers means that for the first time in Cubik’s history we have a full management team without Paul or myself acting as stand ins. This gives the business great stability and ensures team members have direct access to someone who can answer their questions and provide support. It also gives Paul and I a team that can help drive the individual departments, and therefore the overall business, forward for the future.
I look forward to getting stuck into making Cubik as good as it can be with them on board."
Camilla previously worked as a Finance Manager for Propaganda Promotions Ltd and prior to that spent 14 years at a waste paper brokerage where she worked in administration. When the Accounts Administrator left, Camilla asked if she could take over the role as she had a finance background from university and was keen to use it. As the company grew, she took on the HR and Office Management responsibilities as well.
Since joining Cubik in 2017, Camilla has developed her role, taking on the HR function and working closely with the Managing and Operations Directors to steer the business.
“As Cubik’s first in house Finance Manager, I have been able to put my own stamp on the role and really make it my own. There was already a good system in place, set up by Paul and an outsourced accountant, so it was an easy job to take on.
I remember telling Paul that my passions at work are people and numbers and I feel very fortunate to be able to combine these in my new role. As I am already looking after HR it seemed a natural progression to take the role of Business Manager. I am lucky that I have been working closely with everyone in the team for a reasonably long time now, so I already know what a lovely bunch of people they are.
My new role will be an opportunity to get even more involved in the team, and the wider business, than I already am. I love working with people and am good at recognising people’s strengths. Hopefully, this means I will be able to help with business development and the career development of the individual members of my team.”
After working with Cubik many times on a contract basis, Phil became an official Cubite in January 2019. Prior to that, he worked for a number of companies as a contractor, specialising in electronic and embedded software design.
Since joining Cubik as Principle Design Engineer, Phil has worked on several of Cubik’s most exciting projects. He has brought new ideas and direction to the Design Team and business as a whole and has helped to enhance an already great working atmosphere.
“Over the past year, as the business has grown, my role as Principle Design Engineer has naturally developed too. I have taken on more managerial responsibilities to ensure the smooth running of the Design Team and have been working alongside the Project Managers on quotations and proposals. So, my new role will formalise much of the work I have already been doing.
Obviously, these are challenging times for us all. But now that we are back in the office and returning to some form of ‘normal’, I am looking forward to expanding the Design Team and helping Cubik win exciting projects.”
As the UK starts to work towards a new normal Cubik’s situation is also developing.
With the restrictions starting to ease on manufacturing and construction businesses we can gradually return to more normal working conditions.
On the 1 June, our Senior Management Team returned to the office which will has enabled us to be more efficient at managing each department and the business. It has also given us the opportunity to introduce new measures and review our workspaces to ensure safe distancing between stations.
The remainder of the team will gradually return to the office from the 6 July, but this will be dependent on their personal circumstances such as health issues and childcare. As you all know, our team are at the core of Cubik and we are doing everything we can to support their return to work and ensure that they are comfortable with the new measures.
Whilst we are almost back to business as usual at Cubik HQ, we are still taking each day as it comes. We will continue to closely monitor the advice given by the NHS, Department of Health and the Government and will make any necessary adjustments to keep our customers, suppliers, team, and their families safe.
Keep informed and stay safe.
Paul, Sam and the Cubik Team
Back in February, we were joined by Will Beese, a student from SGS College in Filton, Bristol who came to Cubik to do a week of work experience. Will was a fantastic addition to the office and scored tops mark from the team for bringing in cakes and biscuits on his first day.
Whilst at Cubik, Will kept a diary of the different activities he got involved with and what he learned. Find out what Will got up to below:
Day One
On my first day of work experience with Cubik, I started the day with Camilla Saunders (Business Manager) who explained a bit about her role.
Camilla explained her responsibilities which include handling Cubik’s finances and human resources departments for the business and explained what she does to look after her staff in the Business Department. I then got to sit in on the Monday Morning Meeting, where the team discuss the progress of every live project. It was interesting, talking through all the ongoing projects and which customers they were meeting through the week. After the meeting, I was back working with Camilla and spent the morning handling invoices.
In the afternoon, I spent some time with Matthew Weatherburn (Senior Project Manager) and Dan Ford (Project Manager) in the Project Management team. I got to see how they operate and how the business organises all the projects into various files. There are so many different files and if a document is misplaced it could take quite a while to find, so it was interesting to see how that is managed. Paul Mullen (Managing Director) then took me through the networking system of the business and all the back-ups for the back-ups (for the back-ups!) to keep their business safe from cyber-attacks. At the end of the day, I spent a bit of time with Jake Mullen fixing issues that any of the machines where having that might leave them vulnerable.
Day Two
I spent my second day of work experience with the Production Team. They took me through how they look to trouble shoot their circuit boards and I then got to trouble shoot some simple ones myself. I really enjoyed doing this as it was very interesting. Even though the boards are often not very big trouble shooting can be immensely complicated, especially if there is a problem. I was then given an old, small circuit board and a few different components. I used a soldering iron to solder the components onto the circuit board. I really enjoyed doing this as I have not had the opportunity to do anything like that before. It was challenging at times, but I enjoyed the challenge. I was pleased that it was an old board because that meant if I messed anything up it would not affect an ongoing project and create more work for someone else.
Day Three
On my third day I spent the day with Paul preparing some of the old machines that had been collected to be redistributed to other countries’ schools. We had to go through all the computers completely clear all the hard drives. Some of the computers we had to physically open to find out why there not working or add a graphics card. I do not have a lot of experience when it comes to the inside of computers, so I found this very interesting and I enjoyed doing this.
Day Four
On my fourth day, I was with Will Goodman (Software Engineer) experimenting with embedded C. I had only used C# before, so it was good to get experience in a coding language that I’ve not used much before. I had to use the code to program a small business card game. On the game, there is a circle of lights and you must press the button on the card to stop it on the top green light. I was taught how it worked and then had to experiment with it. I did make the game almost impossible by the 4 level!
Day 5
On my final day, I spent most of my time with Callum Young (Placement Engineer) learning about Raspberry Pi. I found this particularly interesting because I did not realise that you could get something that small with the capabilities of a computer. Obviously, it is not as powerful, but I was impressed by how much you could do with it. We did several different things with the Raspberry Pi including taking an LED board and making it do various patterns. For the rest of the day, I was given the Raspberry Pi and asked to see what I could do with it. I experimented with making it run a few different things which was good fun!
Overall, I loved my week at Cubik Innovation! I was made really welcome by everyone and was really interested and impressed by the work they do.
To everyone at Cubik, thank you for having me.
Will
Like us, you will be aware of the developing situation with COVID-19 and the latest measures that have been implemented.
Whilst we still don’t know what to expect over the next couple of months, we do know that for now we must limit our movements, avoid social contact and work from home wherever possible.
Our aim is still to continue to operate to the best of our ability, whilst maintaining the safety of our customers, suppliers, team and their families and, of course, adhere to the restrictions in place.
We will continue to keep everyone updated. Keep informed and stay safe.
All the best
Paul, Sam and the Cubik Team
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