6. Manufacturing and Assembly Plan
To achieve a price point of ~$100 per unit, the manufacturing and assembly process must be efficient and scalable. In this section, we describe how the device can be produced at large volumes, the facilities and techniques involved, and strategies to maintain quality and reliability while minimizing cost. We also outline logistics of sourcing materials and assembling components from different domains (electronics, plastics, etc.) into the final product.
Our manufacturing approach embraces the principles of Design for Manufacture (DFM), ensuring that every component and assembly process is optimized for mass production. This approach has enabled us to reduce costs while maintaining quality, resulting in a product that's both affordable and reliable enough for ocean deployment.
Design for Manufacture (DFM)
Housing & Components
The plastic housing and chamber components use injection molding or vacuum forming with minimal post-processing:
- Multi-cavity tools for producing multiple parts in one cycle
- UV-inhibited ABS or polycarbonate for durability
- Simple geometries and draft angles for easy mold release
Electrode Production
Electrode fabrication leverages existing industrial processes:
- Bismuth coating via slurry casting and baking
- Silver chloride production by electroplating silver onto copper
- Batch processing of hundreds of electrodes simultaneously
Electronics Manufacturing
PCB and electronics assembly utilize established processes:
- Panelized PCB production for volume efficiency
- Automated pick-and-place assembly for components
- Standard components available from multiple suppliers
Power Systems
Battery and solar integration strategies:
- Off-the-shelf components initially, custom form factors at scale
- LiFePO₄ batteries for longevity and safety
- Standardized 20W solar panels with potential for custom shapes
Assembly Line Process
Sub-assembly Preparation
Electronics Integration
Encapsulation
Final Assembly
Testing & Calibration
Packaging
Semi-automated assembly line designed for efficiency and quality control at each stage
The assembly process is designed for both efficiency and quality. Each unit progresses through a series of stations where specific assembly tasks are performed, with quality checks at critical points. Waterproof connectors simplify final assembly, while automated testing ensures each device meets performance standards before shipping.
Manufacturing Network
Plastics & Mechanical
Contract manufacturers specializing in plastic injection, primarily in Asia or other industrial hubs. Steel molds designed for high-volume production.
Electronics Production
Electronic Manufacturing Services (EMS) facilities with automated PCB assembly capabilities and IoT device expertise.
Final Assembly
Regional assembly centers that integrate subsystems, perform testing, and handle local distribution to minimize shipping costs.
Quality & Supply Chain
Quality Control & Traceability
Each unit receives a unique serial number in both physical and digital form, enabling complete traceability throughout its lifecycle. Manufacturing data, test results, and component batch information are stored in a centralized system, allowing us to quickly identify and address any issues that might emerge in the field.
Supply Chain Resilience
Our design prioritizes components with multiple available suppliers, reducing vulnerability to shortages. Key materials like bismuth and silver are globally available commodities, while battery and solar panel supply chains leverage mature industries with gigawatt-scale production capacity.
Scaling Production
Phase 1
Pilot Production
- 100-500 units
- Soft tooling/3D printing
- Design validation
Phase 2
Initial Scaling
- 1,000-5,000 units/month
- Hard tooling investment
- Semi-automated assembly
Phase 3
Mass Production
- 10,000-50,000 units/month
- Multiple assembly lines
- Highly automated process
Phase 4
Global Scaling
- 100,000+ units/month
- Multiple regional facilities
- Continuous cost reduction
The manufacturing plan leverages mature industrial processes to achieve low unit costs while maintaining high quality. By designing with manufacturing in mind, we minimize complexity and part count. The assembly process is straightforward enough to be done in multiple locations globally, which will be crucial as we scale to meet global demand. Quality assurance at every step ensures each device meets performance specifications, resulting in reliable operation in challenging marine environments. This plan provides a clear path to producing CO₂ extraction units at the scale and cost required for meaningful global impact.