ElectroForge specializes in rapid prototyping and evaluation. We forge your raw idea into a tangible, physical prototype before the potentially costly and time-consuming manufacturing batches and compliance testing.
We strike the iron while it is still white hot. By accomplishing all key work phases in-house, we ensure a fast, flexible and cost efficient solution. We utilise our own standardised module framework to guarantee results within a few weeks instead of several months!
To place an order or to inquire more about our services, don't hesitate to contact us via email or through our contact form.
See an overview of our services below:
Have an idea, but don't quite know what it takes to make it a reality? Or perhaps you are wondering about the technical feasibility of your design? Our concept design service takes your idea to a new level: A technical description that is evaluated and used in the next step.
We have developed a framework of standardised electronic and mechanic modules for rapid prototyping. Our prototypes come in three distinct flavours:
- Tier 1 utilizes our standard module framework, great for quick initial evaluation
- Tier 2 combines out standard modules and custom electronics/mechanics
- Tier 3 comprises completely customised design, useful in final prototypes
To ensure quick lead time, we utilise our module framework as much as possible in our prototypes. In addition, we design custom electronics and select proper modules and components for the design. Some electronics, such as switching converters or RF circuits and antennae, can also be simulated to ensure good design results.
Most of our designs employ 8 or 32-bit microcontrollers and our own embedded C framework. Our associates ensure a professional high-level software such as linux. Test firmware demonstrates functional demonstration on the final prototype.
PCB design & manufacturing
PCB layout is designed based on schematics and functional requirements, should custom electronics be required. ElectroForge has a workshop equipped to manufacture and assemble prototype PCBs.
Our popular prototype PCBs are still available for hobbyists. Following services are are offered:
- PCB materials: FR4 0.2, 0.5 and 1.5mm, Aluminum 1mm.
- Size: up to 200x300mm, arbitrary shapes possible.
- Resolution: Minimum trace width 0.1mm, minimum space between traces 0.08mm.
- Copper: 35μm to 105μm copper thickness, single- or double-sided.
- Solder stop mask: Green solder stopmask available.
- Surface treatment: Chemical tinning of flux resin coating.
- No limitations on file type, even properly scaled image files can be used in our process
We can also restore and copy old, burned out PCBs for vintage electronics and spare parts.
Assembly & testing
Finally, Electronics are assembled, powered up and tested. Firmware is uploaded and the design comes to life, ready for next stage or to be delivered to software developers.
A bare-bone electronic device with all electrical functionality specified in requirement specification. Typical use case would be demonstrating functionality and evaluating potential for manufacturing.
An electronic device with easy access for higher level programming.
Design & modeling
We achieve results fast through our mechanic standard modules, which can be modified to suit specific needs. For custom solutions, we create a CAD-model based on schetching. CAD-drawings themselves are used in various available methods of automated production and fabrication.
Extruder-based 3D-printer is used to manufacture enclosures, mechanical parts and even optical components. Many plastics are available for printing, including ABS, PLA, Nylon, Flex and several transparent/optical materials. Printing resolution down to 0.2mm is achievable. Maximum size for a printed object 220x140x150 mm.
An alternative for 3D-printing is to use our modular enclosures or blank industrial enclosures and modify them for the device being developed. Drilling, milling and cutting can be done for most plastics, wood and non ferrous metals such as aluminium and brass. 3D-printed objects can also be further enhanced by tapping threads and installing metal parts for instance.
Several surface treatments are available for finished, professional look. These include roughening, painting, chemical treatment and polishing.
Mechanical presentation model with or without functionality. Typically used for exemplifying the design for use cases, for example, testing whether a hand-held device prototype meets the physical requirements such as switch and button size and placement etc.
A fully functional and physically accurate prototype of the design. These are typically used for final evaluation before production. Ironing out all potential wrinkles in the design at this stage allows for efficient and hassle-free production batch and compliance testing.
A finished & polished prototype for PR events, exhibitions and fund-raising campaigns.
The journey doesn't end here. The main benefit of prototyping is to reveal possible shortcomings and incorporate new ideas and insights. After prototyping, we can take the design to the next level: a production version. We can also manage production batches and compliance testing through our associates.