Manufacturing Update 1: Pre-Production Circuit Boards
Earlier in the week, we began our pre-production run. In order to insure high quality of the final product, we're making 200 units and sending each one through a set of rigorous tests.
In the image above, you can see the first 200 assembled circuit boards from the pre-production run. On the right set of circuit boards, you can see the Bluetooth module (chip with the blue backing), the button (to the left of the Bluetooth module), LED's (to the left of the button), and some other small electronic components. On the left set of circuit boards, you can see some other small electronic components and the USB connector (the black rectangle on the left of each board).
We've began testing these circuit boards for reliability, and we're happy to say that things are looking good for a first attempt. At this point, the circuit boards seem to have no defects with the exception of the USB connector. The connector fails to attach to the circuit board properly a high percentage of the time due to an issue with inconsistencies in alignment on the component itself.
We're using a pick and place robot to secure all of the components to the circuit boards, which means that it's extremely precise at placing components every time. The issue is in the connector itself, the leads are inconsistently placed so the connector isn't attaching to the pads on the circuit board properly every time. Our manufacturing partner has been working tirelessly over the past week to fix this problem, and a few potential solutions have been suggested which will be tested next week.