GNARBOX 2.0

 
 
 
 
 

GNARBOX 2.0 SSD is a rugged backup device for photo and video content creators who prefer to travel without a laptop, enabling professional workflows from the field to the studio.

Based on the learnings of their initial product, the GNARBOX founders wanted to deliver a much more powerful next generation product in a smaller form factor with usability improvements.  

 
 
 
 

Problems to solve

  • The more powerful V2 device required added features and a more sophisticated processor resulting in additional heat to be dissipated

  • To meet MIL-STD-810G for punishing environments, the V2 device required cooling capabilities for the internal electronics, not allowing for vents for air cooling

  • The thermal design could not compromise ID & ID could not compromise the thermal design

  • User buttons and light indicators needed to be capable of working through a sealed enclosure

  • The introduction of a removable battery and dual battery charger

 
 

Concept Validation & Detail Design

Working carefully with the GNARBOX in-house EE team, Spanner reconciled the competing functional requirements of thermal design, industrial design, and manufacturing requirements.

We then advised the precise layout of PCBA components based on learnings from iterative thermal simulations which confirmed the feasibility of solution paths.

 
 
 
 

Manufacturing Development & Production Ramp

The key breakthrough was the development of a breakthrough innovative die cast chassis with multiple overmolds. Major DFMA hurdles were overcome, requiring a rigorous worldwide supply chain qualification to identify and qualify vendors capable of delivering against cosmetic, cost, and engineering requirements.

Spanner then provided in-region support of first shots and New Product Introduction in East Asia to support ramp to mass production.

 
 
 
 
 
 
 

Program Overview

Definition

  • Data transfer

  • Requirements validation & alignment

  • Thermal strategy integration

  • Thermal model verification

  • Feature & I/O design strategies

  • Initial ID reconciliation

  • Final layout & MCO

  • Part breaks & assembly story

  • Part materials & fabrication strategies

  • CMF validation

  • Preliminary BOM verification

Detail Design, Part 1

  • Build & test breadboard prototypes

  • Empirical thermal validations

  • Features/functions validations

  • Sub-assemblies validated

  • Reconcile final ID & assembly constraints

  • Create part-to-part assembly features per assembly story

  • Validate fabrication & assembly strategies with vendors

Detail Design, Part 2

  • Build/Test Full System Prototypes (FEP)

  • Optimize mechanical fit & function

  • Form-factor PCBs

  • Thermal testing

  • Drop/vibe/ingress testing

  • Finalize assembly features

  • Integrate DFM

  • Verify tolerance analyses

  • Draft part & assembly drawings

  • Finalize timelines for fabrication & build

Manufacturing Development

  • Review factory validation test plans

  • Support FAI / EVT / DVT / PVT in-region as needed

  • Review QC objectives & parameters

  • Review Tool Plan & QA

  • Provide engineering support for DFM review & implementation

  • Facilitate supplier communications

  • Enable and advise validation builds in support of GNARBOX’s development schedule and objectives

 
 

Program outcomes

  • Design for Rugged Environments

  • Manufacturable Solutions for ID

  • Assembly Resolution

  • Thermal Optimization

  • In-Region Manufacturing Support

  • Supply Chain Ramp Support 

 

GNARBOX

  • Tim Feess

  • Mike Lemmon

  • Chris Hart

  • Alan Walter

  • Will Africano

 

Spanner

  • Torence Lu

  • Alyssa Kinoshita

  • Jacob Sandoval

  • Joe Watson

  • Niall Macken

 
“Collaborating closely with the GNARBOX team and their partners around the globe was the key to meeting demanding performance requirements against an aggressive development timeline. We’re so thrilled to hear the market reception and favorable user reactions and see them as affirmations of the team’s understanding of their customers and the determination to deliver on a vision.”
— Spanner COO, Torence Lu
 
 
 
 
 

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