From Product Idea to Engineering Package in 3 Hours
How a solar-powered IoT irrigation system for smallholder farms in East Africa went from concept to manufacturing-ready specs using the CAD Lab.
Time
4-8 weeks
3 hours
Cost
$5,000-$15,000
$49/month
Coordination
Multiple freelancers
Single platform
The Challenge
A hardware founder was designing a solar-powered IoT irrigation system for smallholder farms in East Africa. The product needed to be affordable (under $100 per unit at scale), durable enough for outdoor use in equatorial conditions, and simple enough to install without electrical expertise.
Traditionally, getting from a product concept to a full engineering package — CAD models, bill of materials, manufacturing cost estimates, DFM analysis, and matched suppliers — takes 4-8 weeks and costs $5,000-$15,000 in freelance engineering fees.
Product Requirements
Solar-powered with 7-day battery backup
SMS/2G connectivity for remote monitoring
Soil moisture sensors with 50m wireless range
IP65 weather-resistant housing
Target cost: under $100 at 10,000 units
The founder described these requirements in plain English in the CAD Lab. No CAD files, no engineering drawings — just a clear description of what the product needed to do.
What ForgeOS Produced in 3 Hours
A Complete Engineering Package
Product Architecture
Modular design with main control unit (300mm x 200mm x 100mm) plus wireless sensor nodes
UV-resistant polycarbonate housings using standard enclosures to minimise custom tooling
Stainless steel and brass for all water-contact components
Under 50 parts for manufacturing simplicity
Bill of Materials with Cost Modelling
Full BOM with costs at three volumes: 1,000 / 10,000 / 100,000 units
Identified that standard automotive-grade connectors reduce costs by 30% vs custom
Flagged 2G/GSM phase-out risk — recommended dual 2G/NB-IoT capability
DFM Analysis
Recommended design-for-assembly in Kenya or Uganda to reduce import duties
Identified 3 components requiring custom injection moulding and suggested standard alternatives
Designed for field repair with basic tools available in rural hardware shops
Competitive Benchmarking
Compared against SunCulture RainMaker2 ($450), iSense ($250), and basic drip kits ($80)
Positioned the product at $95-100, undercutting smart competitors by 60% with IoT connectivity
Certification Roadmap
CE marking requirements for electronic components
IP65 ingress protection testing plan
FCC/local telecom approval pathway for 2G modules
Solar panel efficiency certification requirements
Matched UK Suppliers
47 UK-based manufacturers matched from the marketplace
Filtered by: injection moulding capability, electronics assembly, IP-rated enclosures
Direct RFQ capability to request quotes from multiple suppliers simultaneously
The Result
$150,000 Grant Secured
The founder used the engineering package to secure a $150,000 grant from Innovate UK's Smart Grant programme, citing the detailed DFM analysis and cost modelling as key factors in the application's success.
“ForgeOS doesn't replace engineers — it gives founders a 10x head start. Instead of spending weeks getting to a first engineering package, founders start with a comprehensive baseline and spend their engineering budget refining, not starting from scratch.”
Ready to Build Your Product?
Start with a free account. Describe your product in plain English and get your first engineering package today.