IVO is developing revolutionary wireless power technology that could change how devices get charged – no cables, no contact points, just efficient energy transfer. It is innovative technology with real market potential, but like many hardware startups, they hit a familiar challenge: their prototype was working on the bench, but it wasn’t performing reliably enough for the critical client demos and production development timeline they were facing.
Their wireless power system had opportunities for improved energy efficiency and thermal management. They needed technical guidance fast, without the overhead of hiring a full engineering team or stopping development to start from scratch.
That’s where iterative product development consulting comes in – flexible, focused problem-solving that meets startups exactly where they are, helping them de-risk their technical roadblocks while keeping their timeline on track.
Root3 has been an invaluable partner in helping IVO rapidly prototype and scale our technology. Their engineering expertise and manufacturing support have accelerated our ability to bring innovation to market
The Challenge
When Technical Roadblocks Threaten Critical Demos
IVO came to us with a challenge that plenty of hardware startups face: their technology worked, but they were ready to scale and looking to make it more manufacturable and reliable. Their wireless power system had opportunities for improved energy efficiency and thermal management, and they had some major client demos on the horizon that needed to go perfectly.
The team was small, focused, and moving fast. But they were also getting tied up with tasks like preparing wire by hand – a task that was eating up over 30 hours per week! That’s so much valuable engineering time eaten up by simple prep work.
They needed help, but they didn’t need someone to come in and redesign everything from the ground up. They needed a partner who could jump in, understand what they were building, and help them solve specific technical problems without slowing them down.
Our Approach: Iterative Product Development Consulting
Understanding Before Advising
The first thing we did was ask questions. What are the biggest risks? Why did you design it this way? How does it work? Where are you seeing opportunities for improvement?
Our consulting sessions started out monthly and pretty informal. No rigid agendas, no drawn-out presentations. Just sitting down with IVO’s team, understanding what they needed help with, and figuring out how to move forward.
As the project evolved and deadlines got tighter, those sessions became more frequent. We stayed flexible, adapting to their needs rather than forcing them into a preset procedure.
Technical Problem-Solving in Real Time
We weren’t there to write a hundred-page report and disappear. Every recommendation we made came with the research and math to back it up, and we prioritized working quickly so IVO could test our recommendations and keep moving.
When something didn’t work, we adjusted. When it did, we built on it. That’s the benefit of iterative consulting – you’re not locked into a single big solution. You’re solving real problems as they come up, and you’re doing it fast.
The Solutions: From Circuit Optimization to Manufacturing Ready
Phase 1: Energy Efficiency and Thermal Management
The biggest opportunity was energy efficiency – transferring more of the energy and losing less to heat. We did some research and testing in order to come back with recommendations for the IVO team.
We also took a look at their board assembly and identified opportunities to improve connection reliability and overall system performance through better assembly practices. Small improvements tallied up together can make a massive difference in reliability!
Phase 2: Preparing for Critical Client Demos
After only a few months, IVO had a demo coming up with a major tech company. We can’t say who, but let’s just say it was the kind of meeting where everything needed to work flawlessly.
So, we focused on performance reliability.
We identified several ways to improve thermal performance and overall system reliability. Our recommendations helped ensure the system would perform consistently during high-stakes demonstrations.
We also tackled that wire sourcing issue. Thirty hours per week of manual wire prep was not sustainable. We sourced MWS wire that was ready to use right out of the box – no peeling, no cleaning. That alone saved them a huge amount of time every single week.
Phase 3: Rapid Enclosure Design and Fabrication
After that demo, IVO came back to us with great news and another request. They had a new demo lined up and they needed a custom enclosure. In only two weeks.
We designed and fabricated the enclosure, handled the wire management to keep everything organized and accessible, and delivered it on time. The enclosure was functional, professional, and ready for a client-facing demo.
We made sure it checked all those boxes.
Phase 4: Design for Manufacturing Improvements
Now we’re continuing to work with IVO on their next phase: building three more units and refining the design for easier manufacturing.
We’re helping to redesign the circuit boards, prioritizing Design for Assembly to make sure it’s easier to assemble. That means the assembly team won’t have to hand-solder components, making everything more straightforward and less prone to error.
We’re also adding labels and organizing the layout so that anyone opening up the enclosure can immediately understand what they’re looking at. When you’re scaling up to build multiple units that kind of clarity makes a real difference.
The Results: From Prototype to Production-Ready
Technical Improvements
The system is running better than ever now! Our recommendations and tweaks to the design has resulted in more reliable performance, more efficient energy use, and improved thermal management.
Business Impact
IVO successfully delivered reliable prototypes for multiple high-stakes client demos. When they needed an enclosure in two weeks for a demo, we delivered. And now, they’re moving from a troubleshooting phase to a manufacturing-ready phase, positioning themselves for growth.
Operational Efficiency
IVO’s team is no longer stuck spending 30 hours a week prepping wire! Plus, assembly is faster and more reliable thanks to Design for Assembly improvements. And the updated layout makes servicing and troubleshooting straightforward.
Why Iterative Consulting Works for Hardware Startups
Flexibility Without
Long-Term Commitments
Not every startup needs a full-time engineering team. Maybe you just need someone who can jump in, solve a specific problem, and get out of the way. Our weekly consulting sessions are flexible and re-engage month to month based on your needs.
From Concept
to Client-Ready
Our support grows with your product development timeline. Whether you’re troubleshooting a prototype, preparing for a critical demo, or transitioning to manufacturing, we’re there to provide the technical guidance that translates to real business results.
Real World
Problem Solving
We don’t chase theoretical perfection. We focus on de-risking the challenges you’re dealing with right now – the ones that are blocking your progress or threatening your timeline. Quick recommendations, fast validation, and actionable solutions.
Facing Technical Challenges in your Hardware Development?
Root3 Labs provides product development consulting for hardware startups in MedTech, Defense, and Aerospace. From design optimization to rapid prototyping, we help you solve problems and hit critical deadlines.
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