Updates
All the pieces I need for the working prototype are either at hand or on their way, so I’m somewhat blocked right now. Once I have the prototype, I can shoot some video and start a KickStarter campaign. The “production” phase depends largely on how much money I raise and how much interest there is, because there are some options that are only feasible at higher volume (and initial capital outlay). The final cost-per-unit will change depending on how many units I plan on making as well.
That said, the minimum quantity to make the whole thing worthwhile is about 100 units. So, for now, I’m looking at what exactly I can build if I can get 100 orders. If I get less, the project is a no-go. If I get more, I’ll know that costs will come down further, and options will open up.
Anyway, here’s an update on the various components:
- Solar panel - I’ve been evaluating the samples I got, but I’m not entirely happy. They’re a tad under-powered, especially as the panel gets hotter in the sun, and they’re starting to warp as well. The backs of the panels are also pretty badly scratched up, which is purely cosmetic, but I wouldn’t feel great selling them like that. So, I’m ordering another batch of samples from another manufacturer, and I’m trying PET laminate coated ones in addition to epoxy. They cost about a dollar more, but supposedly last longer. We’ll see.
- Battery - I’m still waiting for the samples I ordered. In one email they said they’ll ship on the 16th, but in an earlier email the estimate lead time was 15 days… so not entirely sure what’s going on. I might start talking to another supplier too, just to be safe.
- Circuits - The internal battery charger design is more or less fixed. I need to get prototypes made, but that costs money, so I’m waiting until I’ve raised more funds. I contracted someone to design the USB charger circuit, and that’s coming along nicely. The version I commissioned will support outputs up to 2A at 5V, so it should be able to charge power-hungry iPads as well as phones and other small devices.
- Enclosure - The enclosure is still the biggest unknown. The design I came up with previously is fine for the prototype and demo units, but 3D printing is too expensive for the production run. The alternative is injection molding, but it costs thousands of dollars to have molds made, so it’s not economical unless I’m making at least 500 units. So, I’m looking at alternatives. I looked into custom tins (like Altoid tins) but those are also expensive for low volume. A slightly cheaper solution is thermofolded enclosures (which don’t require molds), but they look as cheap as they cost. I’m leaning towards using CNC-cut wood, which is cheap, but will, I think, look different in a good way. Ultimately, I’ll release the key dimensions so that people can design, make, and sell their own enclosures.
In general, the slow pace of development is taking a little getting used to. With web apps (which I was doing for most of the last 12 years), the design-implement-deploy cycle can be as short as hours or days. But with physical stuff, the design-manufacture-ship cycle takes weeks, at best. It’s okay, though. One thing I learned while building my cabin is that, as long as you start and don’t stop, you’ll get there eventually.
