Digitised Wireless Communications Module
A client approached us with a promising concept and functional prototype: a system designed to digitise traditional paging systems within the fire and smoke detecting sector. While effective, the initial version relied on off-the-shelf components not intended to work together. This resulted in a bulky, difficult-to-maintain setup. The prototype enabled repeatable high quality production.
The Challenge
Despite demonstrating proof of concept, the system’s ad-hoc hardware integration presented issues with reliability, serviceability, and scalability. Our task was to refine the product’s architecture to support efficient production, improve durability, and reduce both build time and cost.
Our Solution
We redesigned the system from the ground up, developing custom components and packaging to streamline integration and performance:
Custom PCB 1: System Interconnect
This board served as the system’s central hub, allowing seamless integration of all hardware. Paired with custom cable looms and quick-connect fittings, it improved build consistency, reduced assembly time, and enhanced field serviceability.
Custom PCB 2: Warranty-Safe Interface
This board functioned as a dummy mating plug to connect with an existing component port—without voiding the warranty. By avoiding invasive modifications, we provided a clean, modular connection via custom cabling.
Custom Enclosure
We designed a compact, branded plastic case optimized for installation. The internal layout eliminated wasted space, halving the unit’s footprint while preserving the brand’s look and feel.
The Result
Our engineering-led redesign delivered key benefits:
- Increased build quality and system robustness
- Reduced build time and BoM costs (Assemble went from 47 minutes down to 15 minutes)
- Improved maintainability in the field
- Standardised spares enabled a new service offering
By addressing the weaknesses of the original system and focusing on production efficiency, we helped our client transform a functional concept into a robust, scalable product ready for deployment in demanding environments.
We’re always available to chat about a project, call us at +442081385332 or send an email to info@ie-technology.co.uk
