Manufacturing updates

Hi everyone!

We have quite a few exciting developments happening behind the scenes, and we wanted to share an update on how everything is progressing.

Component situation and PCB assembly:

As we mentioned in the previous update, several components (like the IMU or the MCU) have extremely long lead times of around one year. These components use the same TSMC manufacturing nodes that are also used by many other high-demand components. Unfortunately, the component supply situation is getting significantly worse, with lead times for some critical parts continuing to increase.

We planned around this as carefully as possible and have secured enough chip stock this year to fulfill all Kickstarter orders, cover expected warranty replacements and RMAs, and provide approximately 20% additional inventory for orders placed through our online store. While we are awaiting final confirmation on the delivery date of some of the components, we expect to have them in October-November. 

Although the resulting production timeline is later than we originally planned, securing this allocation gives us the best possible path to fulfilling our commitments as quickly as possible despite the worsening supply situation. We will share an updated Kickstarter project timeline as soon as we are confident that it is accurate and realistic.

Once this initial component allocation has been exhausted, there may be a period during which we are unable to manufacture additional units while we wait for further deliveries of orders that are already placed.

We have one additional component facing a potential delay: the charging dock uses a wireless module based on one of Nordic Semiconductor’s latest ICs, the nRF54LM20. When we selected the module, both the chip and the module were expected to be readily available by now, and that remained the expectation until only a few months ago. Nordic has since had to produce a new revision of the IC to address some RF-related issues, which has in turn delayed production and availability of the module. We are monitoring the situation closely and remain in contact with the module manufacturer, our suppliers, and distributors, while also preparing alternative solutions in case the delay begins to affect our production schedule.

We have also selected (and signed all contracts) with our PCB assembly partners here in Spain. We are currently working with them through the DFM process and preparing the production setup. We expect to begin the first pre-production assembly runs sometime after August.

Injection molding update:

In our last update, we shared the first injection-molded samples of the tracker enclosures. These were the first parts we had produced using injection molding, and although they were an important step forward, we are not satisfied with their cosmetic quality. The surface scratches too easily, and the texture was not pronounced enough to provide the finish and durability we want for the final product.

Since then, we have been testing different materials, textures and surface finishes. Based on the results so far, the final enclosures will likely move away from ABS in favor of either PC or PC+ABS, both of which should provide better durability and a more premium finish.

We are currently working with three different injection-molding suppliers to achieve the best possible results. We have already received samples from two of them, produced in three different materials, and are now comparing their appearance, scratch resistance and overall quality.

Over the next few weeks, we expect to receive additional samples in 5 different materials, all using a new surface finish and gating configuration.

At the same time, we are also finishing the design of the Beacon and charging dock so that both can move into the injection-molding process once we select our final supplier.

New office, manufacturing and logistics space:

We have mentioned the new facility several times, but we have not yet properly explained its purpose or how it fits into the journey of each FluxPose kit from production to delivery.

The final assembly, calibration, quality control, and fulfilment of every device will take place here at our own facilities in Spain.

For this, we have connected and are renovating two warehouses with about 1.000m2 combined. This gives us the space required to manage the logistics involved in mass producing FluxPose kits, from storing humidity-sensitive electronic components to handling tens of thousands of small batteries or storing about a hundred pallets of carry cases, plastics, packaging and finished products.

Additionally, we will have a large clean space for assembly of your devices. For calibration, a large climate-controlled hall is being set up with space for three calibration machines and room for automating the loading and unloading of the devices into these calibration machines in the future. 

In addition to production, the new facility will give us more room to develop future products, build prototypes and film product demonstrations, tutorials and support guides.

The renovation schedule has been one of our many headaches over the past few months but work is now progressing quickly. The new flooring for the calibration space has been laid. Work on the internal walls is finishing, and electrical and fire-safety installations are already underway. Struts to mount climate control and other systems are currently being installed and work on the ceilings will start soon. We expect to be able to move into the space in late September.

Additionally, we have already ordered the heavy and large production and testing equipment we need to mass produce your orders. Machines like industrial laser engravers, automatic screwing machines, environmental chambers, and robotic arms are already sourced and being shipped by boat. This means they will arrive in the new facility even before we move in.

Growing the FluxPose team:

We are growing the team that will help us launch production, progressively automate processes, and develop future products based on FluxPose technology. 

Our original plan was to wait until we moved into the new facility before expanding the team. However, given delays with the construction work, we have decided to bring this forward so that we can move faster and begin building the necessary knowledge and processes before production starts.

The FluxPose team has already grown to a total of 7 people, but we still have several technical positions to fill across different areas. If you are based in Spain or are interested in relocating to join us, you can view our current openings at https://jobs.fluxpose.com. English is the only required language, however we strongly prefer that team members are located in Spain. That said, if you are exceptional at what you do and believe you could make a significant contribution to FluxPose, we may also be open to considering alternative working arrangements.

Certification:

We are now starting the formal certification process for our devices.
A few weeks ago, we visited a local EMC laboratory to carry out pre-compliance testing on the FluxPose Tracker and Beacon. Pre-compliance testing is essentially a rehearsal for the official certification tests. The devices are evaluated using similar equipment and procedures to identify any electromagnetic emissions or immunity issues before the final certification submission.

Both the Tracker and Beacon performed extremely well and passed the pre-testing with flying colors. (They were undetectable, below the noise level of the instruments). This gives us a high level of confidence that the electronic design is ready to move forward into formal certification and production.

We also carried out electrostatic discharge (ESD) testing on every device in the FluxPose system. This simulates the static-electricity shocks that electronics can experience during normal use, such as when a person touches a device after walking across a carpet.

We tested the devices with discharges of up to ±30 kV. None of the FluxPose devices were damaged or permanently affected. At higher discharge levels, typically between 8 kV and 15 kV, some devices temporarily restarted. This is expected when testing significantly beyond normal certification levels, and the devices recovered automatically without damage or loss of functionality.

The only casualty was a slightly questionable wall-mounted USB charger that we were using to power the Charging Dock. It did not survive the ESD shocks :( 

Adapter design:

We are now beginning the design of the adapters required to support different HMDs, gloves, and other accessories. To help with this work, we are using a high-precision 3D scanner to capture the exact geometry of each device, allowing us to design adapters that fit accurately and securely. Our original plan was to publish all of these scanned 3D models on Printables so they would be available for anyone to use to satisfy their deepest modding desires, but we are currently reviewing the potential legal and intellectual-property implications of doing so before making a final decision.