A high-charged collaboration for fast product development
The journey from idea to working prototype can be a multi-year marathon. WiTricity teamed up with Fresco to fast-track the design of their unique wireless charging product for golf carts and NEVs (neighborhood electric vehicles). Through close collaboration, the project advanced from ideation to production-intent working prototypes in just nine months, involving rapid iterations, hands-on development, and thorough testing.
WiTricity is pioneering efficient, safe and convenient future-ready EV wireless charging solutions that utilize patented magnetic resonance technology.
Design Strategy / Industrial Design / Mechanical Engineering / Models & Prototypes
Effortless EV Charging with WiTricity
WiTricity's wireless charging technology offers a game-changing solution for electric golf carts and NEVs. The system features a Power Hub that transmits power to any cart equipped with a WiTricity Receiver. Users simply plug the Power Hub into a household outlet, set up the wheel guide, and start charging within minutes.
The WiTricity Receiver, installed on the cart either at the factory or by an authorized dealer, allows for effortless charging by parking the vehicle over the Power Hub. Delivering robust power transfer, WiTricity ensures quick and efficient charging, enhancing the convenience and efficiency of electric vehicle use.
Turning “what if” into reality
WiTricity needed to demonstrate their unique technology for B2B engagement. An initial conversation and quick whiteboard sketch led to the first rudimentary model, and 9 months later, they had production-intent working prototypes in hand for the WiTricity Power Hub and Receiver.
Front-end design to define &
solve user challenges
With daily hands-on work and seamless collaboration between design, engineering, and model-making, Fresco tackled user challenges head-on. Our iterative approach made the charging system efficient, ergonomic, and intuitive for home installation and use.
Using a weighted model of the WiTricity Power Hub, and rounds of in-person testing, we identified the ideal handle placement for installation.
Design-prototype-test cycles for wheel guides ensured accurate and effortless parking alignment.
We designed vehicle-specific recyclable cardboard guides to ensure correct component placement during installation for maximum charging capacity.
Various NEV carts have a wide range of heights, from low indoor use to higher off-road variants. We developed a riser system to adjust for the correct Power Hub height, ensuring compatibility with a range of NEV shapes and sizes.
Short-run production & advanced materials testing
In this fast-tracked project, our goal was to give WiTricity certainty that their investment in tooling would be smooth. It would fit and perform as expected in mass production methods such as injection molding and metal casting. We explored manufacturing feasibility and tested various methods to validate design and technology integration. Selective anodization of aluminum components was used to weatherproof the exterior while maintaining internal conductivity.
Production-intent prototyping processes
We used a multi-material approach for functional, field-testing prototypes, providing real-world insights:
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CNC'd aluminum with selective anodizing: Mimics production casting performance.
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ABS product cover: matches thickness and ribbing detail of an injection molded part
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Carbon-filled nylon risers: reflects strength of nylon-reinforced injection molding.
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Cast urethane rubber wheel stops: Matches durability and flexibility of production vulcanized rubbers.
A testament to collaboration
The project's success was underscored by the rapid, cohesive collaboration between design, engineering, and model making. This synergy, combined with an iterative approach to prototyping and testing, addressed critical challenges such as wireless charging ranges, heat management, and environmental constraints, culminating in a well-designed, thoroughly tested product ready for the market.
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