Case Studies
NVIDIA Jetson TX2 Carrier & Control Board for Industrial Robotic Vision & Measurement
Scope:
To design a custom electronics platform for a high-performance industrial vision and measurement system. The platform needed to combine NVIDIA Jetson edge computing with the control, communications, power and peripheral interfaces required by the wider system.
Solution:
Spark developed a bespoke NVIDIA Jetson TX2 carrier and control board integrating GPU-accelerated edge computing with high-speed communications, camera and illumination control, RF synchronisation, closed-loop Peltier temperature control, power management and a dedicated microcontroller for real-time system control. The resulting application-specific PCB brings the key processing, control and interface functions together within a compact embedded platform.
End-of-Line 3-Phase Motor Drive Automated Test System 11kVA With Regenerative Load
Scope:
To design, integrate, and deliver a fully automated, high-performance test system housed within a unified 19-inch cabinet enclosure. The system is specifically engineered to execute comprehensive, reliable, and automated End-of-Line (EOL) functional testing of 3-phase motor drives rated up to 450V and 11kVA.
Solution:
A turnkey, fully automated 19-inch rack-mounted test system engineered for End-of-Line functional testing of 3-phase motor drives rated up to 450V and 11kVA. It integrates PXI control, programmable AC power, and custom load-side magnetics with an innovative 11kVA regenerative AC load that recycles energy directly back into the grid to minimise operational costs and carbon footprint. Complete with a modular pneumatic docking fixture, it enables fast, highly repeatable production line testing across multiple drive variants.
Sensory Tag Rugby Belt: Assistive Wearable System for Inclusive Sport
Scope:
To overhaul and engineer a complete, production-ready replacement for a non-functional legacy prototype for the charity Cerebra. The brief required developing a robust, wearable electronic tag rugby belt that provides instantaneous multi-sensory feedback including high-visibility RGB LEDs, an acoustic buzzer, and haptic vibration. Children with diverse sensory needs instantly know when they have been tagged.
Solution:
An end-to-end engineered, high-density wearable system built around a strict Minimum Viable Product (MVP) philosophy to eliminate over-engineering and reduce production costs. Featuring magnetic analogue tag sensing, hardware-level power isolation, 433MHz RF telemetry with antenna and smart BMS docking.
Avionics Power Distribution Management System
Scope:
Develop a custom power distribution and management system for an avionics application where available off-the-shelf solutions could not meet the required Size, Weight, Power and Performance (SWaP) constraints.
Solution:
Spark Product Innovation developed a compact multi-module electronics architecture designed specifically around the available mechanical envelope. Custom power distribution electronics and wiring harnesses were designed and manufactured to interconnect the modules, delivering a tightly integrated system that met the application’s packaging and performance requirements.
High Speed FPGA and Firmware
Scope:
Develop a custom high-speed FPGA pattern generator with multiple high-speed I/O channels for use within an advanced quantum computing application.
Solution:
Spark Product Innovation designed a custom PCB incorporating ultra-high-speed differential routing, carefully engineered termination networks and the supporting digital electronics required for reliable signal integrity. The associated FPGA firmware was also developed in-house, providing the customer with a complete turnkey hardware and firmware solution.
Stingray Squash Ball Machine
Scope:
Develop an early proof-of-concept squash ball launcher into a reliable, cost-effective product suitable for user trials, demonstrations and eventual volume manufacture. The work included resolving key performance limitations before completing a full turnkey electronics, software and mechanical redesign.
Solution:
The resulting Alpha 2 prototype delivered significant improvements in size, weight, ergonomics, usability and overall performance. The electronics, software and mechanical systems were redesigned as an integrated product platform, producing a more refined and manufacturable system suitable for the next stage of commercial development.
Spark Product Innovation – Company Introduction
Overview:
Spark Product Innovation is a multi-disciplinary engineering consultancy supporting customers from early concept through to production-ready product development. The team combines electronics, embedded software and mechanical engineering to provide an integrated turnkey development service.
Capabilities:
Core expertise includes high-speed digital electronics, analogue and power electronics, embedded software, digital signal processing and FPGA development, alongside mechanical packaging and product integration. Founded in 2017, Spark Product Innovation applies this cross-disciplinary experience to complex engineering challenges across a wide range of industries.