Last week saw a significant milestone for aerosensor, as T1 sample models of our production plastics arrived.

T1 samples are the first shots off the new moulds, with no surface texture applied.  These allow us to check the fit and function of the parts, before starting final production.

We’re delighted to say that they exceed our expectations and pending a couple of minor internal changes we have lift off.  The next step is for the suppliers to produce another set of samples which will be as production to check surface finish.  When we give the go-ahead after that they will manufacture production volumes.

Images of the built-up products with these T1 samples are shown below.  The white parts are TPE – a rubber like material which allows us to create waterproof buttons and flexible USB bungs.  These will be black in the final version.

We are on track to receive production quantities in the second half of June for shipping to our indiegogo backers.

T1 Samples of aerobody, aerodrome and aerosensor.

Next week we expect to see the first production circuit boards.   We will test these thoroughly before going straight into full-scale production.  Since we are using a local manufacturer, we can test the boards on the same day they are assembled, allowing a rapid turnaround.

We are also arranging assembly of all three devices with the same company who are assembling the circuit boards – we can’t stress enough how useful it is to have everything so local, makes refinement and quality control so much easier and the high standard we must achieve for accurate scientific instruments.

Through our final production design phase we have had to make some minor changes to the aerosensor device.  Although the changes are very minor, since accuracy is critical we have booked a day in the wind tunnel at Bristol university to calibrate the device.  This 240-point calibration is embedded in the device firmware to achieve a highly accurate airflow data which is the foundation of a solid CdA measurement.

In other news we also received plain packaging mock-ups – stay tuned to see further sneak previews to see the results of our recent social media vote on packaging design.

Prototype packaging for aerobody, aerodrome and aerosensor.

From this point forward plan to release an update at least every two weeks – this is the most exciting part of our 5 year journey, seeing the consumer product take shape.  Things are moving fast so we will endeavour to keep you posted on progress, currently the aim is to allow the public to pre-order all of our devices in the next few weeks on our website, so keep an eye out.