Inside the Ultrahuman Factory: The Creation of a Smart Ring
Smart rings rank among the most compact and subtle forms of wearable technology available today. Specifically designed to monitor sleep, activity, heart rate, and more, these miniature devices incorporate an impressive array of technology into a sleek, finger-sized design. But what is the process behind bringing a smart ring to fruition?
During a recent visit to Ultrahuman’s new manufacturing site in Plano, Texas, Michael Hicks from Android Central gained a firsthand view—and practical experience—of how the Ultrahuman Ring Air is produced. The process, although complex, was unexpectedly enjoyable and straightforward. Here’s what we discovered.
Step 1: Crafting the Brain – Printed Circuit Boards (PCBs)
The adventure starts with the development of the smart ring’s brain: the printed circuit board (PCB). These PCBs contain all the critical elements, such as:
– System-on-Chip (SoC)
– Photoplethysmography (PPG) sensors for heart rate monitoring
– Inertial Measurement Unit (IMU) for tracking movement
– Temperature sensors
– Bluetooth module
These components are affixed to flexible PCBs composed of fiberglass, polyamide, and ceramic materials. A single machine can produce up to 10,000 PCBs each day, but currently, Ultrahuman’s output is around 400 rings per day, which is projected to increase to 1,350 each day by the end of 2025.
Step 2: Quality Assurance – Internal and External Inspections
Before advancing, every PCB undergoes thorough quality assessments:
– X-ray machines check the internal structure for defects.
– High-resolution cameras examine for outer flaws.
– Software is loaded onto the PCB to ensure it operates correctly.
Only after successfully passing these evaluations does the PCB progress to the next phase.
Step 3: Soldering the Components
The next stage involves the meticulous process of soldering:
– The Rx (receiver) coil is soldered onto the PCB.
– The battery is then affixed to the coil.
This task is performed manually, necessitating a steady hand and precision. Excess solder is carefully brushed away to create a smooth, flexible assembly that can conform to the ring’s rounded design.
Step 4: Assembly – Installing the Electronics into the Ring
With the electronics prepared, the components are shaped into a J-curve using a 3D-printed tool. Workers apply adhesive inside the titanium-carbon ring shell, peel off the adhesive backing from the PCB, and insert the electronics into the ring.
A quick software check verifies that the ring is operational before it transitions to the next stage.
Step 5: Resin Casting – Finalizing the Product
To safeguard the internal components, the ring is placed in a silicone mold and filled with epoxy resin. This procedure occurs within a vacuum-sealed chamber to avert air bubbles. However, it is the most time-consuming segment—requiring 24 hours to cure naturally. Heating the resin to accelerate the process could jeopardize the delicate electronics.
Step 6: Polishing and Final Assessments
After the resin has cured, the ring is extracted from the mold and polished. Workers utilize electric brushes, sandpaper, and buffing solutions to smooth out any imperfections. This ensures the ring is comfortable and visually appealing.
A final software check and sizing test ensure the ring is ready for packaging and sale.
An Engaging Experience
During the factory tour, Hicks seized the chance to engage in the manufacturing process. He soldered components, placed the electronics into a ring shell, and even polished a nearly finished ring. While he didn’t complete the entire 24-hour resin curing step, his partially assembled ring will eventually reach a customer—making him a proud contributor to the production process.
Obstacles and Future Developments
Despite the remarkable process, smart ring manufacturing still encounters challenges:
– Resin casting is a bottleneck due to its prolonged curing duration.
– Repairability is restricted since the resin renders access to internal components nearly impossible.
– Battery replacement is currently unviable owing to the sealed design.
Ultrahuman is investigating potential solutions, including:
– A concealed reset button for firmware updates and diagnostics.
– More efficient casting machines capable of handling multiple rings simultaneously.
– Long-term aims for modular designs to facilitate easier repairs and battery replacements.
Conclusion: A Renewed Appreciation for Wearable Tech
The Ultrahuman factory tour highlighted the extensive craftsmanship, precision, and quality control involved in crafting a smart ring. Though the process may seem straightforward at a glance, it encompasses a complex mix of manual skill and advanced machinery.
As smart rings progress, manufacturers like Ultrahuman are not only enhancing their production methods but also reimagining how these tiny devices can become more sustainable and user-friendly. Thus, the next time you wear a smart ring, you’ll appreciate the effort that went into its creation—and perhaps even recognize who played a part in its production.
