Pokit Clamp Update #17: Production Challenge & Looking Ahead

Hi Everyone,

This month we've made excellent progress across most areas of production, but we've also encountered an unexpected manufacturing challenge that has temporarily slowed us down.

While this isn't the update we were hoping to share, it's exactly why we spend so much time validating our production process before products reach customers. We'd much rather find these issues now than after you've received your Pokit Clamp.

Production Update

There has been plenty of good news over the past few weeks.

• ✅ Production PCB assemblies have now been manufactured and are being programmed successfully.
• ✅ Plastic moulded parts are being produced and meeting our expectations.
• ✅ Production test jigs, calibration systems and manufacturing processes are all performing well.

Unfortunately, we've identified one critical component that isn't yet meeting the quality standards we require.

Core Manufacturing Issue

At the heart of every Pokit Clamp is a precision magnetic core. It's one of the most critical components in the product and demands extremely tight manufacturing tolerances.

During our pilot production run, we built 40 units, with 38 passing first time and only 2 requiring rework. That gave us confidence we were ready to move into production.

However, once we scaled up, we saw a significant drop in consistency. From the first 115 production cores, only 15 met our quality standards. This forced us to pause production and assess.

The issue isn't the measurement performance itself; it's the dimensional consistency of the cores. Small variations in size mean that when the cores are overmoulded with their protective plastic insulation, some develop cracks in the overmoulding. Since this insulation forms part of the clamp's electrical safety system, even very small cracks are unacceptable, and those parts must be rejected.

Below we've included a few photos showing examples of these cracked parts so you can see exactly what we're dealing with.

Although this has been a frustrating setback, it's exactly why we validate production before shipping products. Pilot builds don't always reveal the same manufacturing challenges that appear when you scale from tens of parts to hundreds.

We're now working with a new manufacturing partner to produce replacement cores that consistently meet our specifications. If everything goes to plan, we're expecting this to add approximately 2–3 weeks to the schedule while the new parts are manufactured and verified.

If we still can't achieve the consistency we require, we may need to make further changes to the production process, which would unfortunately extend the timeline further. That's not the outcome we're expecting, and we're doing everything we can with the new supplier to minimise the delay.

App Update

Development of the new Pokit App continues to progress really well.

The beta program has been providing fantastic feedback, and we're incorporating improvements every week. We're currently targeting a full public release within the next 6 weeks.

This release introduces the brand-new architecture and user interface that will become the foundation for future features, including Power measurements and the new Power Analyser module along with many more updates that will roll out over the coming months.

Looking Ahead

Right now, everything else is ready. The electronics, firmware, plastics, packaging and production systems are all in place, we're simply waiting on this final component before production can continue.

As soon as we receive and verify the new cores, production will restart immediately, and we'll share another update with photos and progress from the production line.

We know delays are disappointing, especially this close to the finish line, and we sincerely appreciate your patience. Thank you for continuing to support us and for believing in what we're building. We're committed to delivering a Pokit Clamp that lives up to the expectations you've placed in us, and we won't compromise on that.

Until next time,

The Pokit Innovations Team