From Project To Kit: Bringing It All Together

This is the fourth article in a series examining the process of turning an electronic project into a marketable kit.We’ve looked at learning about the environment in which your kit will compete, how to turn a one-off project into a costed and repeatable unit, and how to write instructions for your kits that will make your customers come back for more. In this article we will draw all the threads together as we think about packing kits for sale before bringing them to market.

If you had made it this far in your journey from project to kit, you would now have a box of electronic components, a pile of printed instructions, and a box of plastic bags, thin card boxes, or whatever other retail packaging you have chosen for your kit. You are ready to start stuffing kits.

It’s All In The Presentation

Label all your hard-to-identify components, your customers will appreciate it.
Label all your hard-to-identify components, your customers will appreciate it.

Your priorities when stuffing a kit are to ensure that your customer receives all the components they should, they can easily identify each component, and that the whole kit is attractively presented such that it invites them to buy or build it when they first see it. This starts before you have packed any components, you must carefully prepare each component into units of the required number and label them if they are otherwise not easy to identify. Pre-cut any components supplied on tape, and write the part number or value on the tape if it is not easily readable. You may even have to package up some difficult-to-identify components in individual labeled bags if they can not have their values written on them, though this incurs an extra expense of little bags and stickers. Some manufacturers will insist on using black tape on which an indelible pen doesn’t show up!

Take care cutting tapes of components, it is sometimes easy to damage their pins. Always cut the tape from the bottom rather than the side with the peelable film, and if necessary carefully bend the tape slightly to open up the gap between components for your scissors.

If you start by deciding how many kits you want to stuff in a sitting, list all the kit components and prepare that number of each of them in the way we’ve described. Then take the required number of packages or bags, and work through each component on the list, stuffing all the bags with one component before starting again moving onto the next. In time you will have a pile of stuffed kits ready to receive their instructions and labeling.

The next step will be to fold your instruction leaflet and pack it in the kit. Take a moment to consider how it can be most attractively presented. For example with a kit packaged in a click-seal plastic bag it makes sense to fold the leaflet such that the colour photo of a completed kit is visible from the front. And when you place it in the bag make sure that the PCB is visible top-outwards in front of it. A customer looking at your kit wants to immediately see what they are likely to create with it.

LED-flasher-kit-labelYou can now seal the bag or box, the kit is packed. It only remains to give it a label that has all the pertinent information and is attractive to the customer. You will probably want to put your logo or web address on the label as well as any small print required, alongside the most important feature — the kit description. We’ve put a warning about small parts and curious children, you may also want to put any reglatory or compliance information here. For example in Europe you might have a CE mark and a WEEE logo. Once you have your design sorted you can run it up in your favourite label designing software – we used gLabels – and print as many as you like on sheets of sticky labels. We strongly suggest buying good quality branded labels, the extra money is well worth it when you consider that they will have much more reliable glue, and the extra cost per individual kit will be marginal. Pick a label size which fills a decent space and is easy to read on your packaging without being too big, we used 70mm x 37mm laser labels of which 24 can be had on a single sheet.

Your First Finished Product

if Hackaday made electronic kits, they might look a little like this.
If Hackaday made electronic kits, they might look a little like this.

It’s an exciting moment when you apply a label to your first fully packed kit and see for the first time what your customers will see: a finished product. You aren’t quite done though, because there is still the small matter of quality control. Take a kit or two from your batch at random, and count all their contents off against your list of what they should contain. This should help you ensure you are packing the kits correctly. Finally, give a completed kit to a friend who has never seen it before, and tell them to build it as a final piece of quality control. They are simulating your customer in every way, if they have no problems then neither should anyone who buys the kit.

Once you’ve built your batch of kits, you will now have the stock you will send out to your customers. Imagine yourself as a customer, if you order a kit you will expect it to arrive in pristine condition. You should therefore now take care of this stock of kits to ensure that it does not come to any harm, its packaging is as crisp and new when you send it out as when you packed it, and it has not attracted any dust while in storage. We would suggest having a separate plastic box for the stock of each kit in your range, and protecting the kits from dust with a lid, or by storing them inside a larger plastic bag.

As we’ve worked through this series of articles, we’ve tried to give you a flavour of the process of bringing an electronic kit from a personal project to the masses. We’ve looked at learning about the market for your kit, we’ve discussed turning a project into a product before writing the best instructions possible and now stuffing your first kits ready for sale. In the next article in the series we’ll talk about how you might sell your products, the different choices open to you for online shops, marketplaces, and crowdfunding.

Hacker Builds New Single Board Computer Out of Old Single Board Computer

[Ncrmnt] had a busted tablet PC with an Allwinner A23 SoC inside. He combined two of our favorite past-times, Linux hacking and 3D printing, to make a rather sweet little single-board-computer out of it, giving the tablet a second life.

Step one was to make sure that the thing works. Normally, you’d hook up a wired serial terminal and start hacking. [Ncrmnt] took it one step further and wired in a HC-05 Bluetooth serial module, so he can pull up the debug terminal wirelessly. The rest of the hackery was just crafting a bootable SD card and poking around in the Android system that was still resident in the flash memory of the system.

Once the board was proven workable, [Ncrmnt] designed and printed a sweet custom case using Solvespace, a constraint-based 3D CAD modeler that was new to us until recently. The case (after three prints) was a perfect fit for the irregularly shaped system board, a 3.7 V LiIon battery, and a speaker. He then added some nice mounting tabs. All in all, this is a nice-looking and functional mini-computer made out of stuff that was destined for the trash. It’s fast, it’s open-source, and it’s powerful. Best of all, it’s not in the dumpster.

There are pictures and more details on his blog, as well as [Ncrmnt]’s TV-stick to computer conversion that we’ve covered before.

From Project To Kit: Instructions Are Everything

A printed copy of the instructions for our example kit
A printed copy of the instructions for our example kit

We’ve had two previous articles in this series on turning a personal electronic project into a saleable kit, in which we’ve examined the kit market in a broader context for a new entrant, and gone on to take a look at the process of assembling the hardware required to create a product. We’ve used an NE555 LED flasher as a simple example , from which we’ve gone through the exercise of setting a cost of production and therefore a retail price.

The remaining task required to complete our kit production is to write the documentation that will accompany it. These will be the instructions from which your customers will build the kit, and their success and any other customers they may send your way will hang on their quality. So many otherwise flawless kits get this part of the offering so wrong, so for a kit manufacturer it represents an easy win into which to put some effort.
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Homemade EDM Can Cut Through Difficult Materials Like Magnets With Ease

Many years ago [ScorchWorks] built an electrical-discharge machining tool (EDM) and recently decided to write about it. And there’s a video embedded after the break.

The build is based on the designs described in the book “Build an EDM” by Robert Langolois. An EDM works by creating lots of little electrical discharges between an electrode in the desired shape and a material underneath a dielectric solvent bath. This dissolves the material exactly where the operator would like it dissolved. It is one of the most precise and gentle machining operations possible.

His EDM is built mostly out of found parts. The power supply is a microwave oven transformer rewired with 18 gauge wire to drop the voltage to sixty volts instead of the oven’s original boost to 1.5kV.  The power resistor comes from a dryer element robbed from a unit sitting beside the road. The control board was etched using a hand traced schematic on the copper with a Sharpie.

The linear motion element are two square brass tubes, one sliding inside the other. A stepper motor slowly drives the electrode into the part. Coolant is pumped through the electrode which is held by a little 3D printed part.

The EDM works well, and he has a few example parts showing its ability to perform difficult cuts. Things such as a hole through a razor blade., a small hole through a very small piece of thick steel, and even a hole through a magnet.

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From Project To Kit: Getting The Hardware Right

In the previous article in this series on making a personal electronic project into a saleable kit, we looked at the broader picture of the kit market for a new entrant, the importance of gauging whether or not your proposed kit has a viable niche and ensuring that it has a good combination of buildability, instructions, and quality. In this article we will look at specifying and pricing the hardware side of a kit, illustrating in detail with an example project. The project we’ve chosen is a simple NE555 LED flasher which we haven’t built and have no intention of assembling into a kit for real, however it provides a handy reference project without the circuit itself having any special considerations which might distract from the job at hand.

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DIY Linux Computer and 6LoWPAN Gateway

We toss together our own PCB designs, throwing in a microcontroller here or there. Anything more demanding than that, and we reach for a Raspberry Pi or BeagleBone (or an old Linksys router). Why don’t we just whip together a PCB for a small Linux computer? Because we don’t know how…but [Jonas] apparently does. And when we asked him why he did it, he replied “because I can!”


His Ethernet-to-6LoWPAN gateway project is a small, OpenWRT-capable Linux computer in disguise. Rather than yet another Raspberry Pi project, he designed around an Atmel AT91SAM9G25 400 MHz CPU, and added some memory, Ethernet, and a CC2520 radio chip to handle the wireless side. It’s all done on a four-layer board, and hotplate/skillet reflowed. This seems temptingly like something within our reach. [Jonas] had access to X-ray machines to double-check his reflow work, which probably isn’t necessary, although it looks really cool.

When finished, the project will link together a 6LoWPAN network (probably home automation) and his home wired network. That makes this device a rival to something like Philips’ Hue Bridge, which was the subject of some controversy when they locked out other devices for a few days until they recanted. Indeed, in response to this, there’s been quite a lot of effort at hacking the firmware of the Hue device, just to stay on the safe side in case Philips plays shenanigans again.

Soon, that’s not going to be necessary. [Jonas]’s design is open from the ground up, and coupled with open software running on top of the OpenWRT router operating system, that’s the full stack. And that’s great news for folks who are thinking about investing in a home automation technology, but afraid of what happens then the faceless corporations decide to pull the plug on their devices.

Electrostatic Loudspeakers: High End HiFi You Can Build Yourself

If you have an interest in audio there are plenty of opportunities for home construction of hi-fi equipment. You can make yourself an amplifier which will be as good as any available commercially, and plenty of the sources you might plug into it can also come into being on your bench.

There will always be some pieces of hi-fi equipment which while not impossible to make will be very difficult for you to replicate yourself. Either their complexity will render construction too difficult as might be the case with for example a CD player, or as with a moving-coil loudspeaker the quality you could reasonably achieve would struggle match that of the commercial equivalent. It never ceases to astound us what our community of hackers and makers can achieve, but the resources, economies of scale, and engineering expertise available to a large hi-fi manufacturer load the dice in their favour in those cases.

The subject of this article is a piece of extreme high-end esoteric hi-fi that you can replicate yourself, indeed you start on a level playing field with the manufacturers because the engineering challenges involved are the same for them as they are for you. Electrostatic loudspeakers work by the attraction and repulsion of a thin conductive film in an electric field rather than the magnetic attraction and repulsion you’ll find in a moving-coil loudspeaker, and the resulting very low mass driver should be free of undesirable resonances and capable of a significantly lower distortion and flatter frequency response than its magnetic sibling.
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