Production Status

Final Pre-Production Adjustments: Q3-Q4 2020

Extreme: First pre-production model in testing. A new pre-production model has been shipped and just arrived this week and testing has commenced.

Extreme: Review of extra safety measures. Our team reviewed the safety measures for all Extreme power banks. In addition to the 500A lithium-polymer battery (note for reliability and tested over an extended period) the 12V output has a protective cap as standard and uniquely, in our experience — silicon insulating tips on both metal poles to minimize the chances of a short circuit from a foreign metal object.

Air: Second pre-production model tested. This model resolved almost all issues and Air is very close to production readiness. However, we identified three issues which precluded final sign off for tooling: (1) Qi latency: a delay before Qi charging begins, (2) Qi coil resonance: a slight ‘buzzing’ sound when charging. An updated pre-production model is being prepared.

Life: Second pre-production model tested. The second unit arrived and is 95% correct: excellent mechanical results, all ports charging as specified, LEDelicious working almost perfectly. We found minor problems with this model: (1) LEDelicious wired to indicate charging on incorrect port numbers (2) coil resonance. An updated pre-production model is being prepared.

Final Engineering: Q2 2020

Road: Stabilizers. We tested the torque exacted on a vertically-mounted 12V car outlet and finalized the stabilizer design required to ensure that Road fits firmly and snugly.

Wall: Package expansion. It turned out that, even using GaN, there were severe space constraints for Wall. Much of the interior is taken up by the tip mechanism and wall prongs leaving precious little for charging circuitry. The system is based on a standard width across all products, so that could not be increased — hence we made the decision to expand the depth, front to back, which far more than doubles the total space available for circuit boards in current and future models. As an added benefit, future products will also be able to use a variant of this form factor.

Final Engineering: Q1 2020

Extreme: Extensive work on prioritizing power distribution among devices that exceed the total power output capacity of the device. Because Extreme has so many output ports, it’s possible to draw more current than this unit is capable of delivering. We made the decision to share power pro rata among all ports: every device being charged continues to charge at a proportionately slower rate.

Extreme: Final engineering on multiple power outputs — resolved technical challenges relating to 3xQi + USB outputs rated up to 18W combined in a single unit with jump-start capability. Extreme is a truly first-of-a kind product with a unique combination of features in a single package. We made a series of decisions that resolved the challenge of combining high-energy-density required for maximum phone charges with lower-density high-current needed for jump-start ‘burst’ output.

Extreme: Selected lithium-polymer battery chemistry for performance and safety. We made the decision to specify a higher-cost battery based on the new lithium-polymer technology which offers a higher performance/safety combination than lithium ion. Our research indicates that competitive batteries deliver a bigger charge (unnecessarily) and burn out after a relatively small number of jump-starts. Lower-quality battery chemistry can also leak and swell, causing the outer casing to crack. We selected a 500A battery — lower current than many alternatives, but powerful enough to jump-start numerous SUVs and trucks on a single charge, much safer, more reliable and offering significantly longer battery life.

Product range: Feature alignment between all family products. User experience inconsistencies between different products in the range were identified and aligned. All products in the range now use the same circuitry decisions to ensure consistent LED performance, charging prioritization among ports, etc.

Extreme: Tested 18,500 mAh lithium-polymer battery with multiple vehicles. The first lithium-polymer batteries selected for MAGFAST arrived in the U.S. and we tested their 12V jump-start abilities with a range of different vehicles, up to and including a 5.4-liter Ford F150. The first series of jump-start tests were on Jan 23, 2020 and resulted in a failed dongle that had to be diagnosed.

The second series of tests were on Feb 7. We tested with several different safety-protection dongles: the lower cost dongle blew up on the first attempt while cranking a large truck engine. The premium dongle worked flawlessly and a fully charged Extreme successfully cranked the truck engine 6 times before being depleted to a point where the dongle shut off the current.

Road: Final engineering changes to maximize utility while plugged into 12V car port. We worked extensively on Road to maximize its utility for use in-car. Total USB outputs were increased to 3 x USB-C (18W) plus 3 x USB-A (shared XW) to allow up to six vehicle occupants to charge simultaneously at maximum power. We finalized engineering of the circuit board to bypass Road’s battery while the device is plugged into a 12V car output: full current is now delivered direct to USB outputs. Road auto-senses when it’s no longer plugged in and switches to battery power.

Road: Flashlight engineering. A series of decisions were required for completion of the flashlight assembly, including the stabilizers (to ensure that Road stays plugged in during travel) and the light reflector. After testing several different versions, we determined that the beam cast will be broad (floodlight rather than spotlight).

Time: Redesigned to allow larger battery. Our engineering team had made some choices to allow MFi (Apple’s Made-for-iPhone/iPad certification program) compliance that significantly reduced the battery size. We reconsidered the constraints and managed to expand Time’s battery capacity substantially.

Time: MFi compliance for charging disc. Apple’s MFi certification is fastidious over the physical positioning of the charging disc for Apple Watch. Great care is required to ensure that a watch is charged successfully, doesn’t fall off the disc, or otherwise fail to charge. We completed this work successfully and submitted to Apple for final MFi certification.

Product Range: MAGFAST magnets specified. We tested numerous magnet options and finally found the right units with the correct dimensions and pull force. Our original intention was to position the magnets underneath the plastic case. However, this option proved unworkable because the added distance between magnets diminishes the pull force exponentially. The final resolution was surface-mounted N52 magnets with a durable hardened white-epoxy coating.

Wall: SP2X upgraded to 30W GaN. The latest Gallium Nitride (GaN) semiconductor technology allows much smaller charging components that operate at lower temperatures. We made the decision to add cool, compact GaN to Wall with the intention of expanding possibilities, starting with an increase in USB-C power output to 30W for Wall SP2X.

Life: Functioning sample received with MAGFAST connector functioning — power in/out fully operational.

MAGFAST’s Products

Designing and engineering different products simultaneously, each best-in-class, has been more complicated than we expected. Completion of the engineering process was also hit in the first half of 2020 by COVID-19 but we are now pleased to report excellent recent progress in finalizing the entire product range.

Taking on the design of an entire family of products all at the same time has been a monumental task for such a small company. But there have been some benefits of this “design and engineer everything together” approach:

  • We knew from the outset this was the only way we knew we could deliver a seamless, integrated experience. Because MAGFAST is a family of devices, we have designed consistent, intuitive behavior across all products.
  • Some products have presented unique challenges – but many features are common across the range. We have been able to solve many engineering challenges once, then apply the solution across the entire family.

MAGFAST products are designed and engineered to exceptionally high standards, and we are planning a manufacturing process which will be driven by the same quality expectations. Our manufacturing partner has a full-scale testing facility which allows us to ‘burn in’ (test) all units to ensure an infinitesimally small failure rate: every MAGFAST device will be put through a comprehensive testing cycle before packing and shipping.

Click on the More… links below for a detailed, up-to-date view of status and timeline for each product in the family.

Air

STATUS

► Pre-production sample approval expected: August 2020
► First shipments to earliest backers expected: December 2020

Air is designed to revolutionize your experience of wireless charging

Air was an exciting challenge for our engineers: it’s the only induction charging system with two Qi-Wireless coils (one vertical, one horizontal, so you can charge your phone standing up or lying down) combined with snap-to-charge technology. We tested numerous ways of snapping Air to other MAGFAST-family products and found the perfect-strength neodymium magnets. Our original plan to have the magnets located invisibly under the case proved too hard to implement, so we ultimately settled on surface magnets with a beautiful, hardened white-epoxy coating.

Work complete:

  • Pre-production working sample tested
  • Snap-to-charge technology tested/finalized
  • Multiple power IN (MAGFAST x 2, Micro-USB, USB-C) tested/finalized
  • Multiple power OUT (Wireless x 2) tested/finalized

Work to be completed:

  • Development is now complete with the exception of a small clearance issue with the adjustable Wall tips during a final check on 6/30/20. This will cause a slight delay in the Air pre-production sample relative to Life and Extreme.
  • Neodymium magnets using white epoxy coating tested using Air prototype : will be consistent across the range.

Milestones:

Life

STATUS

► Pre-production sample approval expected: August 2020
► First shipments to earliest backers expected: December 2020

Life packs an unprecedented range of features into a small-but-mighty power bank

Life is a powerful charging system that combines the features of several wired and wireless chargers and power banks in a very small package. Our first challenge was to fit all those features inside the case. The Life pre-production sample we received in December 2019 was an exciting moment for the team: our first opportunity to verify so many ports simultaneously receiving and delivering charge.

Work complete:

  • Pre-production working sample tested
  • Multiple power IN (MAGFAST, USB-C, Micro-USB, Wireless) tested/finalized
  • Multiple power OUT (MAGFAST, USB-C, USB-A, Wireless) tested/finalized
  • Final mechanical/design improvements
  • Development now complete and signed off by MAGFAST; updated pre-production sample expected shortly
  • If this sample is error free, we move into tooling and final steps to production

Work to be completed:

  • LED system in final stages of engineering/testing
  • Pre-production sample to be approved: expected August

Milestones:

Extreme

STATUS

► Pre-production sample approval expected: August 2020
► First shipments to earliest backers expected: December 2020

Extreme is the world’s most capable AND flexible advanced power bank

Extreme presented a series of unique engineering complexities. A major challenge was finding a battery that carries enough charge to recharge your phone multiple times and current with the punch to jump-start your car. The battery passed our tests with flying colors on everything from a sedan to a 5-liter truck (in Texas!). Our engineers also had to figure out management of a large number of ports all working simultaneously, and the complexity of making it easy for you to understand what’s charging, what’s charged, and how quickly. And, with so many output ports, we had to address the challenge of what happens when you plug in too many items together (the answer: keep charging everything, just more slowly).

Work complete:

  • 18,500 mAh High-power/high-current battery tested
  • Multiple power IN (MAGFAST, USB-C, Micro-USB, Wireless) tested/finalized
  • Multiple power OUT (MAGFAST, USB-C x 2, USB-A x 3, Wireless x 3) tested/finalized
  • Updated form factor (original ‘boxy’ case switched to long, slender design)

Work to be completed:

  • Power prioritization system in final stages of engineering/testing
  • Production sample to be approved: expected {month}
  • Development now complete and signed off by MAGFAST; updated pre-production sample expected shortly
  • If this sample is error free, we move into tooling and final steps to production

Milestones:

Road

STATUS

► Pre-production
► First shipments TBA

Road is with you in your car or your boat - anywhere with 12V power

Road is another small package with a wealth of features. Road plugs into the 12V “cigarette-lighter” port in your vehicle: we envisage you and up to five family and friends all wedged into your seats charging phones and tablets using USB-A and USB-C. We used a new design approach to fit all the components and to channel power from the car’s electrical system to all those ports, bypassing the battery. Of course we also needed to ensure the electronics switch seamlessly to battery power when you unplug from the 12V port or turn off the vehicle’s ignition.,.  On the mechanical side, we added spring-loaded stabilizers to ensure Road stays put when hitting bumps and potholes. Surprisingly difficult? Fitting a powerful broad-beam flashlight neatly into the same space as the 12V plug. But we’re doing it:  we believe it will be the first of its kind.

Work complete:

  • Multiple power IN (MAGFAST, USB-C, Micro-USB, Wireless) tested/finalized
  • Multiple power OUT (MAGFAST, USB-C x 3, USB-A x 3) tested/finalized
  • Flashlight prototypes evaluated

Work to be completed:

  • Final flashlight design
  • Production sample to be approved: expected {month}

Milestones:

  • TBD

Wall

STATUS

► Pre-production
► First shipments TBA

Wall is the ‘invisible base station’ that charges all other MAGFAST devices

Wall is the only MAGFAST-family product that plugs directly into a standard outlet, which brings extra safety requirements including UL-standard certification through ETL, our selected independent testing lab. Wall operates both as a pass-through device (power direct from the house power receptacle ) and as a multi-output charger.

High-quality low-resistance circuitry for the pass through allows maximum reliability, and an equivalent high-quality circuit helps ensure faster charging through the  .

Substantial engineering investment in the Wall range has allowed us to pack more ports and more power than we believed possible. The release version of Wall offers 4 output charging ports, together delivering a maximum of 28.5W:

  1. MAGFAST top 10.5W**
  2. MAGFAST bottom 10.5W**
  3. USB-C tip on top 18W
  4. USB-A 2 ports on bottom sharing 10.5W

**  The top MAGFAST port can not be used at the same time as the charging tips and the bottom MAGFAST port can not be used at the same time as the bottom ports. 

Work complete:

  • Multiple power OUT (MAGFAST x 2, USB-A x 2, USB-C bottom port, 110V x 2, Micro-USB tip, USB-C tip, Lightning tip)
  • Power-supply circuit design

Work to be completed:

  • Design finalization: TBD
  • Production sample to be approved: expected TBD
  • UL (ETL) certification

Milestones:

  • TBD

Wall SP

STATUS

► Pre-production
► First shipments TBA

Wall SP is the MAGFAST family’s ‘invisible base station’, including surge protection

As with the Wall standard, engineering for the Wall base station is now complete. {?}

Wall SP details as Wall standard, with the addition of surge protection circuitry.

Work complete:

  • Multiple power OUT (MAGFAST x 2, USB-A x 2, 110V x 2)

Work to be completed:

  • Production sample to be approved: expected {month}
  • ETL certification

 Substantial engineering investment in the Wall range has allowed us to pack more ports and more power than we believed possible. The release version of Wall SP offers 4 output charging ports, together delivering a maximum of 28.5W:

  1. MAGFAST top 10.5W**
  2. MAGFAST bottom 10.5W**
  3. USB-C tip on top 18W
  4. USB-A 2 ports on bottom sharing 10.5W

Work complete:

  • See Wall

Work to be completed:

  • See Wall

 Milestones:

  • TBD

Wall SP 2X

STATUS

► Pre-production
► First shipments TBA

Wall SP2X is the MAGFAST family’s ‘invisible base station’, including surge protection + double the power

Wall SP2X has proven to be the most ambitious product to engineer in the Wall series. The addition of USB-C along with two MAGFAST snap-to-charge connections, space taken by the 110V plugs and the mechanical interface for the flexible charging tips meant there wasn’t enough room in the case for all the electronics using conventional charging technology. Our engineers adopted a brand-new form of charging circuitry based on gallium-nitride (GaN) semiconductors which can sustain much higher voltages running at cooler temperatures in a much smaller space. The exciting result (referenced here for the first time !) is that Wall SP2X now has not one but two USB-C fast-charging ports: 18W on the top and 30W underneath.

Wall SP2X has 5 output charging ports for the “Double The Power” version of Wall supporting a max power of 58.5W:

  1. MAGFAST top 10.5W**
  2. MAGFAST bottom 10.5 W**
  3. USB-C tip on top 18W
  4. USB-C port on bottom 30W
  5. USB-A 2 ports on bottom sharing 10.5W

Work complete:

  • See Wall

Work to be completed:

  • See Wall

Milestones:

  • TBD

Time

STATUS

► Pre-production
► First shipments TBA

Time is the ultimate charger for Apple Watch

Time is a dedicated product for Apple Watch and the only device in the MAGFAST line-up requiring MFi (made-for-iOS) certification from Apple. Many lower-quality devices sidestep Apple’s certification requirements, which means they could be withdrawn or will at some stage cease to function. Design and engineering to meet Apple’s standards took our team several months, complicated further because Time allows your Apple Watch to be oriented vertically or horizontally. Apple’s most stringent requirements relate to the precise physical positioning of the charging disc to ensure the Watch is successfully charged and unlikely to fall off. After meeting Apple’s standards for electronics and industrial design, there was insufficient space for a suitable battery. The design team (led by Seymour) then worked with the engineering team to resolve this final challenge.

Work complete:

  • Industrial Design (ID)
  • Apple MFi certification

Work to be completed:

  • Design finalization: TBD
  • Production sample to be approved: expected TBD

Milestones:

  • TBD

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