A company specializing in reselling e-bikes and modification kits approached Henway Engineering because they needed help taking their proof-of-concept electronics design from prototype to production. The company had developed all the necessary electronics to cater to DIY e-bike enthusiasts, but one product in particular—a tiny e-paper display showing the remaining battery charge— was giving them trouble and needed expert assistance to reach its full potential.
The e-paper display was an excellent choice for the application because it’s sunlight-readable and doesn’t consume battery power when the e-bike is off. However, the design lacked ESD protection and had random glitches that they must address before mass production. The company came to Henway for help with programming the display, adding ESD protection, and modifying the hardware to improve their production yield, which had been problematic up to this point due to the BGA.
We began the project with a thorough design review phase. Our team analyzed the proof-of-concept schematic and code, identifying several areas for improvement. After discussing our findings with the client, we re-estimated the project scope and moved forward with the new design and producing samples.
After a brief prototype production run and block testing of the new hardware, we passed the samples to the customer and got great feedback. They said the project was successful and will take their latest design to their existing production partner. We haven’t heard from them since. I check their website from time to time, and this product is still proudly featured on their website. Seeing this makes me happy. Good job, everyone!
This project illustrates Henway Engineering and Manufacturing’s commitment to supporting our clients at any stage of their product development journey. Whether you’re fine-tuning a design for production or need help solving specific technical challenges, we’re here to ensure you make it across the finish line and into the hands of your customers. Contact us.