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UltraStrike: Electronics Prototyping and PCB Design

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UltraStrike: Electronics Prototyping and PCB Design

Project snapshot

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The LA New Product Development Team delivered UltraStrike: Electronics Prototyping and PCB Design. The work sits in our iot & consumer experience, where we take an idea from concept through design, prototyping and manufacturing readiness.

The client

Benjamin Morris is a product developer and an entrepreneur from Ruston, Louisiana. He is the inventor of UltraStrike, an arc lighter for welding torches. The idea for this invention came from the need to have a reliable tool for his welding works. Mr. Morris approached our PCB design company when he had already made the first rough prototype of his invention himself. Now he needed the PCB layout services to further the product development process of the arc lighter.
PCB Design Services, UltraStrike: Arc Ligter, LA NPDT

The challenge

PCB Design Services, UltraStrike: Arc Ligter, LA NPDT
The PCB layout services were required to develop a fully-functional arc lighter that could serve as a presentation of the product before launching manufacturing of the first batch. Mr. Morris wanted the PCB layout to represent the final product design while withstanding demonstrations with real welding equipment. One of the tasks our team was presented with included building proof-of-concept and pre-production prototypes. During the prototyping stage, we aimed at minimizing production costs while improving the performance of the device.

Our solution

Our PCB design company started electronic prototype development by analyzing the original prototype Mr. Morris had. We then designed the electronic schematic that would be able to generate a continuous arc. Having built and tested a proof-of-concept breadboard electronic prototype, we compiled a Bill of Materials (BOM), completed PCB layout services, and made a prototype. From there, we designed and 3D printed the enclosure for the electronic parts. While designing the enclosure, we considered injection molding requirements and limitations. After successfully testing the prototype, we finalized the design and prepared it for manufacturing.

The result

Our team not only created a realistic 3D CAD Model of the product and designed the electronic circuit, but we also delivered a functional prototype within a rather short period of time. By utilizing rapid prototyping expertise, our PCB design company helped Mr. Morris move to the mass production stage. Furthermore, electronic prototype development allowed for design modifications that optimized the efficiency of manufacturing. This resulted in lower production costs and better performance.
PCB Design Services, UltraStrike: Arc Ligter, LA NPDT
PCB Design Services, UltraStrike: Arc Ligter, LA NPDT
PCB Design Services, UltraStrike: Arc Ligter, LA NPDT
PCB Design Services, UltraStrike: Arc Ligter, LA NPDT
If you looking for a PCB design company to turn your product into something you could hold in your hands, show to investors, or use for recording a promo video

PCB design project at a glance

ScopeSchematic capture, multilayer PCB layout, BOM, prototype boards
Typical stackMicrocontroller, power regulation, sensors, wireless connectivity
DeliverablesSchematics, Gerbers, BOM, assembly drawings, tested prototype
Typical timeline4-10 weeks from requirements to a tested board

What a PCB design company is responsible for

The board is where cost, size, battery life and reliability are decided. That means selecting parts that will still be available in two years, laying out power and ground so the device passes EMC, keeping analog away from switching noise, and leaving room for the test points that make debugging possible.

Our process

  • Requirements first: power budget, interfaces, size envelope, certification targets
  • Architecture and part selection against availability and lifecycle
  • Schematic capture with review before layout begins
  • Layout with attention to stack-up, return paths and thermal relief
  • Prototype build, bring-up and firmware validation on real hardware

Frequently asked questions

How much does PCB design cost?

A simple two-layer board typically runs $2,000-$6,000; a multilayer board with wireless and mixed-signal sections generally runs $10,000-$40,000 including bring-up.

Do you also write firmware?

Yes. Firmware, bring-up and test scripts are handled by the same team that designs the board.

Can you design the enclosure around the board?

Yes - mechanical and electrical are developed together, which avoids the usual late-stage fight over connector positions.

Capabilities used on this project

Industries this project belongs to

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