Case Studies
Jack Fuse
..better product design
than I had ever imagined.
Ken McKeon
JackFuse
Revolutionising Emergency Door Release Systems with Remote and Automatic Reset Capabilities
The Jack Fuse Electronic Break Glass (EBG) represents a significant advancement in security technology, offering the first automatically and remotely resettable break glass unit. This innovative solution eliminates the need for manual site visits to reset emergency door release systems, reducing costs and enhancing security for fire safety providers and access control installers.
Services delivered
- Concept Development
- Industrial Design
- Prototyping
- Testing
- Manufacturing
Project goals
Jack Fuse’s main goals were to develop an advanced wall-mounted enclosure for the electronics security and access control market that would address critical limitations in existing break glass technology:
- Eliminate the need for manual site visits to reset break glass units
- Reduce operational costs associated with emergency door release maintenance
- Enhance security by minimising the time doors remain unlocked unnecessarily
- Create a retrofit-compatible solution for existing installations
- Target fire safety installers and security providers with an innovative alternative
Features
The Electronic Break Glass offers groundbreaking features that set it apart from traditional manual reset units:
- Multiple Reset Modes: Automatic, remote, and local reset with override capabilities
- Removable Activation Guard: Lift-up guard for added protection against accidental activation
- Advanced User Interface: LED backlighting with adjustable brightness and warning sounder with adjustable volume
- Enhanced Security Monitoring: Built-in tamper switch and two 3A contacts for door release and monitoring
- Retrofit Compatible: Footprint and mounting pattern matching legacy break glass units for ease of upgrade
- Robust Power Management: Low power mode operation with voltage tolerance down to 9V DC
Results
Industry Recognition and Media Coverage
- Featured in Security Electronics and Networks (SEN) publication, highlighting the innovative remote automatic reset capabilities
- Recognition for solving time and cost savings challenges in the security industry
Customer Testimonials
Ken McKeon provided a 5-star review of Paraform’s work: “The team at Paraform have an incredible ability to interpret my chicken scratchings and produce a better product design than I had ever imagined. Not only do they meet design requirements, they have also suggested enhancements and changes that have added real value to my products.”
Market Impact
- First-to-market solution offering automatic and remote reset capabilities for break glass units
- Addresses industry-wide challenge of manual reset requirements that previously necessitated costly site visits
- Provides retrofit compatibility, enabling easy upgrades for existing installations
Let’s bring your product to market
About the project
Requirements
We worked closely with the client to identify their exact feature requirements. Once the must-have, potential and nice-to-have features were clarified, we then analysed their existing components and PCBs.
By taking the time to understand the existing product design deeply, we were able to identify flexible and economical design solutions to achieve EWS’ goals. We also identified new areas in the designs that could be adapted to meet the new aesthetic goals of each product line.
In particular, our process uncovered (and delivered) the following requirements:
- 2x antenna options (cellular and satellite)
- An external contingency antenna option for applications with poor reception
- IP68 rating and waterproofing
- Bluetooth pairing options
- Rechargeable and replaceable battery options
- Accounting for the sensitivity of the sensor mounting materials to ensure accurate readings
- Practical PCB mounting designs that are easy for technicians to work with in the field
Concept Design
After the initial consultation, detailed research was conducted to provide Jack Fuse with a comprehensive design plan that overcame key challenges for bringing their product to market. Multiple rounds of concept development were delivered, with the design iterated and improved through active collaboration.
Using sketches, the team started bringing the initial designs to life, designing for simplicity, elegance, quality and feasibility.
Detailed hand sketches, helped the client visualise potential ways the new components could look and how they could blend their requirements with practical functionality. The drawings included concept diagrams and sketches showing placements of switches, cables, mounting solutions and internal components, along with design for manufacturing considerations and component selection.
Engineering
There were many design challenges that needed to be addressed through careful and deliberate engineering. In particular, the precision engineering approach solved the following challenges:
Tight space and design limitations, especially for internal components. Limiting the amount of plastic components used.
Ensuring designs did not require new injection moulds, which can be costly.
Maximising commonality between parts and accessories across the entire product range.
Finding a more economical and elegant solution to ensure an IP68 waterproof rating.
To achieve an IP68 rating and make the design waterproof, Jack Fuse’s initial design required each device to be filled with resin. This solution meant that parts could not be adjusted later on, not to mention it was rather costly!
The expert team explored many alternative solutions to assist the client. The final design is able to be waterproofed easily by technicians out in the field with minimal use of specialist tools and components.
Prototyping
Working closely with manufacturers, Paraform rapidly developed the first working prototypes of the Electronic Break Glass to test functionality before beginning manufacturing. The final design created was easily prototyped and tested using two in-house 3D printers.
A rapid prototyping process was implemented to test the designs for size and fit, conducting both environmental testing and functional testing. Due to the tight fit needed to achieve optimal performance, the design was iterated in stages to ensure the optimal balance between aesthetics and functionality.
High-quality, detailed prototypes were created using resin printing technology that accurately reflected the final product. Due to the environmental nature of these products, extensive materials testing was conducted to evaluate the strength and toughness of different materials under field conditions.
Manufacturing
With completed design files and tested prototypes, Paraform sourced an appropriate manufacturer from their network of partners and collaborated closely with Jack Fuse to ensure all components were created exactly as envisioned.
The team provided comprehensive 3D manufacturing files, materials sourcing, component sourcing, and BOM management. They also assisted with manufacturer procurement and tooling manufacturing requirements. Essential design work included rubber seal components to ensure a snug fit and maintain the critical ISO rating of the product.
Working with the manufacturers, Paraform helped arrange appropriate packaging and logistics for delivery of the production run. The Electronic Break Glass has since been launched and is now available to the market, representing a successful end-to-end product development from concept through to market delivery.
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