Case study

Challenge

• Our customer approached us seeking our smallest vibration motor, to integrate into their complex luxury smart watch.
• They were struggling to find a motor that could fit within their envelope and had minimal current draw.
• Low energy drain on the battery was vital, combined with high shock resistance, longevity and wide temperature operating conditions.

Solution

• We worked closely to evaluate our selection of in-production micro vibration motors. None of them were optimised for the space and power constraints.
• The customer had enough volume to justify tooling up a new motor specific to their needs. We reused subcomponents where possible to shortened the development time, and prepared a motor that met their technical requirements without multiple design iterations.

Results

• We were able to design in customised leads and suggest a micro connector, to save even more valuable space in the watch case.
• We supplied over 250,000 motors through the COVID-19 pandemic without any delays.
• Demand for the watch held strong through 2020 and production risk mitigations, prevented the customer from losing sales and valuable commercial opportunity.

STAGE 1

Designing for application

• Size constraints on this project were very important. We manage to design an extremely small vibration motor that could still deliver a good haptic feedback.
• The smart watch had a compass and therefore the magnetic field generated in the motor was a potential issue. We helped quantify and mitigate this problem.
• We were able to design in customised leads and a flat connector to save even more valuable space in their device.
• Due to their specific constraints, we worked closely with them on a number of options which we both tested extensively.

STAGE 2

Manufacturing and testing

• They had a very clear time frame on when they wanted to launch their product, which was not flexible.
• We were able to shorten the development time offer a product that met their technical requirements, and avoided multiple design iterations.
• We designed end of line testers to test every motor, and adapted our lab testing machines with a specific test protocol to test in detail motors from each batch. The design worked well – we have experienced minimal variants in the performance results. This offers peace of mind to our customer, who is reassured by the quality consistency.

STAGE 3

Results and relationship

• We have supplied over 250,000 motors to the customer through the covid 19 pandemic without any disruption to their manufacturing lines.
• Our customer relationship was built on trust, integrity, and our ability to manage their risk.
• Our engagement at an early prototype stage facilitated this success, along with meeting the customer needs in an open and professional way.
• After scoring the highest supplier grade, the customer has appointed us as a preferred supplier, due to our rigorous quality testing control and assurance processes.