Concept to First Prototype
Skateboard Body
I started off by sketching up my idea in Solid works. Then started to plan a method of fabrication using the tools I had available. The best way would have been to use a CNC router, but because I didn't have access to one, chose to use a combination of laser cutting, and a jigsaw for thicker pieces, then gluing the layers together.
Version 1 Sensors
Strip FSR
The first version of the sensors used 2 long force sensing resistors (FSRs). The result was absolutely horrible. Because the sensors were so narrow, it would give poor readings of weight distribution. If the user was wearing a shoe that wasn't completely flat, the shoe may not even contact the sensor at all.
Pre Production Prototype
Utilized more outsourced parts, rather than manufacturing by hand
At this point I started to look for suppliers who could manufacture parts for us. In this prototype I used wider sensors which worked a lot better than the previous strip sensor, but was still a little small. I would eventually work with the supplier for our sensors to create custom Force Sensitive Resistors that span the entire width of the deck.
Test Batch & Market Validation
After testing the pre-production prototype to work out as many issues as I could, I planned a trip to China to visit our potentials suppliers and optimize the design to be mass produced. Nearly every aspect of the board was redesigned to be made more efficiently. For this test batch, I decided to go with a wooden deck, so that if we needed any design changes, we wouldn't have to pay for the tooling cost. Additionally, changes for CNC cuts are almost immediate.
ESC Logic Board
To control the motors, I decided to design a custom logic board that would take in the inputs from our FSRs and send signals to a production ready ESC. This would allow features that we needed, such as Bluetooth compatibility and app connectivity, while reducing our time to production.
Final Production Model
After our initial test batch, I was able to collect a lot of data from our customers and was confident enough to finalize the design and purchase tooling to create an injection mold for our deck. This would bring the unit cost down drastically, as well as provide better water resistance and overall durability.