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Product Development and Testing

From Concept to Proof-of-Concept in Weeks

 

Actutec's Power Pod design is developer-friendly: Open Bill of Materials (BOMs), off-the-shelf components, and a modular architecture mean you can spin up a bench prototype for under $1,000 and validate performance in 10–15 hours of assembly. Whether you're an OEM like Rivian prototyping e-bike integrations or a contractor testing home backups, here's what's needed to get running—focusing on our 4-pod portable frame (1–4 kW, ~10 kg) as the entry point. All specs draw from our October 2025 refinements; full blueprints and firmware repos available under NDA.

 

Required Skills and Tools

  • Team/Expertise: 1–2 engineers with basic mechatronics (soldering, Python scripting) and machining familiarity. No PhD required—leverages Raspberry Pi ecosystem.

  • Workspace: Clean bench (4' × 2') with ventilation for gas preloading; access to 3D printer/CNC for custom clamps (or outsource via Shapeways).

  • Essential Tools:

    • Multimeter/oscilloscope (e.g., Rigol DS1054Z, $300–400) for waveform/ripple checks.

    • Torque wrench (5–10 Nm) and calipers (±0.1 mm tolerance) for assembly.

    • Bike pump + adapter for 20–50 bar preloads; phone accelerometer app for vibe testing.

    • Laptop for ECU flashing (GitHub firmware) and app pairing (Bluetooth/WiFi).

Materials and Sourcing on request. Estimated cost is roughly $1,000

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Step-by-Step Build Process (10–15 Hours)

  1. Fabricate Pods (4–6 hrs): Machine/bore chambers; insert pistons/coils; seal and preload gas (30 bar start—monitor stroke w/ caliper).

  2. Assemble Frame (3–4 hrs): Snap dovetail rails; daisy-chain bus/I2C; mount control pod and flash ECU firmware (Python for phase-sync, auto-on >50W).

  3. Integrate & Startup (2–3 hrs): Connect tail/ports; battery-kick nudges (12V pulses); verify 60 Hz AC harvest (1 kW net/pod).

  4. For Subsets: Add U-clamp/SnapCharge (1 hr) for e-bike; trailer frame (extra 4 hrs) for EV.

Testing Protocol (5–10 Hours, Iterative)

  • Bench Validation: Oscilloscope for efficiency (85–90% gross-to-net), ripple (<5%); multimeter for surge (100–200% peaks, 1–2 sec). Run 1M-cycle sim (firmware loop) for durability.

  • Field Trials: E-Bike: Mount to TM-B equiv., log +20% range (app telematics). EV: CCS pigtail mockup, sim 50-mile extend. Genset: Load bank (e.g., 2 kW heater) for auto-on/off; thermal derate >60°C.

  • Safety/Compliance: GFCI tests; IP65 seals; burst pressure check (75 bar rating). Document for non-provisional patent evidence.

  • Scaling Tips: Post-4-pod, add solar trickle ($50) for hybrid; outsource CNC (Taiwan, $200/10 pods) for 100-unit runs.

This low-barrier path de-risks development—prototype in weeks, iterate to market in months. Partner with Actutec for licensed kits, shared IP, or OEM co-dev. 

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