Projects That Demonstrate Our Capabilities

Challenge

Acquiring high-quality sleep EEG signals typically requires a clinical environment. The challenge was to extract weak brainwave signals from a limited forehead contact area with ultra-low noise interference, and process data in real-time to improve the user's sleep — all in a comfortable, non-invasive wearable form factor.

Our Scope

End-to-end pre-research and prototype development covering the complete IoT loop — from low-level hardware (analog front-end and mechanical design) to upper-layer software (App and cloud architecture).

Technical Approach

• Hardware & Mechanical: Ergonomic wearable structure for all-night comfort. Ultra-low-noise analog front-end (AFE) circuit for precise forehead EEG signal acquisition.
• Firmware & Communication: Embedded firmware for raw physiological data processing; stable real-time BLE streaming to mobile device.
• Software & Ecosystem: Mobile App for sleep data visualization; cloud platform with AI-assisted deep/light sleep cycle analysis; closed-loop acoustic stimulation mechanism to extend deep sleep duration.

Key Deliverables

• Custom ultra-low-noise EEG acquisition PCBA prototype
• Embedded firmware with closed-loop acoustic stimulation logic
• App beta for data visualization and interaction
• Cloud AI data analysis platform architecture

Challenge

The client wanted to bring an innovative smart health monitoring concept to the consumer market quickly. The device required integrating multiple sensors and wireless modules within an extremely compact enclosure — demanding elegant aesthetics, comfortable ergonomics and challenging mass-production yield control.

Our Scope

Turnkey product development — leading the entire process from industrial design to volume manufacturing, including mechanical engineering, electronics, software development and supply chain onboarding.

Technical Approach

• Electro-mechanical integration: High-density PCB layout and precision mechanical design to fit complex curved surfaces; safe battery placement meeting drop and waterproof test requirements.
• Firmware & interaction: RTOS-based firmware with optimized sensor data fusion; instant BLE pairing with mobile device.
• Mobile development: Cross-platform App providing intuitive health data dashboard, device OTA upgrades and historical trend tracking.
• Production control: Deep collaboration with assembly factory — custom test fixtures, assembly SOP, bridging the final gap from R&D to mass production.

Key Deliverables

• Tooling-ready 3D mechanical CAD data
• Reliability-validated PCB manufacturing files and BOM
• Published App on App Store and Google Play
• First batch of QC-passed golden samples for mass production

Challenge

The client had a lab prototype that passed initial proof-of-concept but faced low assembly efficiency, unpredictable lead times for key components and high defect rates. The challenge was to restructure the product for tens-of-thousands-per-month production volume without changing core functionality.

Our Scope

Led the New Product Introduction (NPI) process — bridging the engineering and supply chain gap between "working prototype" and "mass-manufacturable product."

Technical Approach

• DFM & cost optimization: Reduced screw count, adopted snap-fit and ultrasonic welding; replaced 3 high-cost end-of-life chips — achieving 22% hardware cost reduction.
• Tooling & pilot production: Managed injection mold development, resolved sink marks and weld-line issues; executed EVT/DVT/PVT three-stage trial production to validate the full assembly line.
• Quality & delivery: Developed automated PCBA test fixtures; established strict QC inspection standards; designed retail-grade drop-safe packaging; delivered first 10,000-unit batch.

Key Deliverables

• Optimized cost-reduced BOM with alternative component specifications
• Production injection molds and automated test fixtures
• Complete manufacturing SOP and quality inspection reports (SIP)
• Custom retail packaging and first 10,000-unit delivery