Technical Services

Delivering rapid, cost-effective product development optimised for manufacturing

Technical services is an umbrella term for a whole range of activities designed to deliver rapid, cost-effective product development optimised for the production line.

From buying materials and organising documentation to prototyping and ensuring products conform to a specific build standard, the emphasis is on managing a product into low-volume or mass production.

The secret of success is risk assessment to understand what actions need to be taken to keep a project on schedule – specifying the parts that will be needed, for example, and making sure they can all be obtained in time.

An extensive network of supplier relationships helps with sourcing components at short notice for rapid assembly of prototypes, while in-house expertise enables custom parts to be fabricated and assembled to meet deadlines and cost requirements

Real-world challenges

Hybrid TETRA-LTE GPS smart tracker

Protection of coastal borders is vital to help target smugglers and prevent illegal entry. The challenge from ATLAS Telecom was to deliver an innovative marine tracking solution as part of its next-generation E-Passport programme.

Resilient and secure communications were required, with seamless operation, along with a high level of tamper resistance, power efficiency and a robust marine enclosure for protection under extreme conditions.

The Plextek team’s work included the design and high-volume manufacture of an advanced military-grade hybrid TETRA-LTE GPS smart tracker device to provide lifesaving features for rescue teams during emergencies.

Using new product introduction management, the product was designed and delivered to the client during the Covid pandemic – which involved setting up and managing plastic tool development and new subcontracted manufacturing in Malaysia.

As no visits could be made to the manufacturing site, the test equipment had to be designed and assembled locally, shipped to Malaysia and linked to a Plextek-designed network server to allow test control from the Plextek office with real-time test yields.

mmWave for autonomous vehicle testing

Autonomous vehicles must be capable of sensing their environment – including moving objects and people. So when Cranfield University needed a radar designed for its autonomous vehicle testing facility, the millimetre-wave (mmWave) radar antennas required waveguides to extend the effective range.

As the production volume was low and the geometry was difficult to achieve with machining, the Plextek team decided to 3D print the waveguides and use a novel process to copperplate the plastic.

As the facility was outdoors and the radars needed to be mounted permanently, the enclosure needed to be sealed to IP66 standards to protect against dust and water – and also be resistant to the sun’s UV rays.

In addition, the system generated 15W of heat, which needed to be dissipated through a passive heatsink. The enclosure also had to allow the radar’s signals to pass through, so material selection and wall thickness were chosen carefully with regards to the wavelength being used.

Key skills

One of our Engineers in the lab
  • Prototype service

    Either in-house or using local sources, creating electronic/mechanical samples before expensive tooling needs to be started.

  • 3D printing

    As part of prototyping, we have a selective laser sintering (SLS) 3D printer (159mm x159mm x295mm model size).

  • CAD modelling

    Expertise to analyse heat dissipation in a fully functional product system.

  • Mechanical design

    Using the latest Creo design software.

  • Siemens PADS or Altium Designer PCB layout

    Extensive expertise in the design of RF, analogue and digital high-speed PCB layouts for rigid, rigid-flex and flexible circuits.

  • New product introduction (NPI) and design for excellence (DFx)

    Management of all aspects of product development from a manufacturing point of view. Creation of a timeline structure for just a few prototypes or stepping stones to full production.

  • Supply chain management

    Advising on the choice of best contract manufacturing services and customised part manufacturing vendors to match the business model and create the best partnerships for the future. Complete bill of material (BoM) analysis to avoid using parts close to obsolescence, prevent critical part shortages and understand the lead time ready for builds.

  • Design for factory product test

    Developing test solutions which best match the business model with the capabilities for delivering a complete solution either to a client or to a contract manufacturer.

Over the years, Plextek has shown that it has the experienced engineers to take a client’s idea and evolve it into a working product. This is combined with the best project management methods to move a design into mass production – making sure all aspects of manufacturing are taken into consideration, so that each project hits its budgets, quality levels, timelines and longevity of product considerations.

Paul Twinn, Manufacturing Specialist
Paul Twinn

Manufacturing Specialist

What sets us apart when it comes to technical services?

The Plextek manufacturing team has extensive experience in delivering products to support new technologies and growth markets such as radars, sensors and space. Our work includes:

  • 3D printing
  • Altium Designer
  • BoM analysis
  • CAD modelling
  • Creo
  • Custom manufacturing
  • Design for manufacturing
  • Manufacturing prototype timelines
  • Mechanical design
  • NPI
  • PCB layout
  • Product development management
  • Prototype service
  • SLS
  • Supply chain management
Contact Plextek

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Projects

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