Electrical Design
Mechanical Design
Software Design
Manufacturing
Test Engineering
Plastics
Optics
Prototyping
Validation
Documentation

ELECTRICAL DESIGN:
Excalibur's electrical design services span the breadth of 34 years, generating countless designs, layouts and software integrations. We are proficient in low power circuits, RF up to the UHF band, High power systems, microprocessors, state machines and ultra low cost consumer circuits. We can design to meet FCC regulations for both emissions and susceptibility.

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MECHANICAL DESIGN:
Excalibur has been providing mechanical design services since 1982, while many designs are for enclosures; we also do kinematics, including designs such as latches, pump heads, gearing and electromechanical interfaces. We use both Solid Works, and AutoCad to develop and document each design. With over 50 years of combined design experience, we can draw from the best thinking of many ages and synthesize innovative and unique designs as some of our patents show.

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SOFTWARE DESIGN:
Excalibur has been in the software business since 1978. Some of our early software and validations set standards for FDA documents as medical equipment entered the programmable silicon age. Dr. Fon Brown, Phd EE, drives our software. Fon also holds degrees in Computer Science, math and electrical engineering. We specialize in embedded systems but often write applications for Windows. Bug free robust code on predictable time lines is our goal, and our top down design with bottom up build has provided that time and time again.

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MANUFACTURING:
Manufacturing support is a key component of new product designs, and Excalibur has been in the trenches since the days of discrete semiconductors. Excalibur has spun off a quality circuit board house and full service assembly shop. Today we focus on Alpha and Beta builds to insure the success of our designs and provide prototypes for our customers' new products. Excalibur can direct completed designs to both overseas and domestic manufactures or train personnel in place for new companies.

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TEST ENGINEERING:
Besides designing quality into products, testing often must accompany a successful product launch. Excalibur provides consulting services and support for new products, and often for products that just need an updated or streamlined process. We can assist companies in their efforts to establish Quality Acceptance and Quality Control standards. We have often been called upon to build specialty equipment to support Test Engineering's needs.

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PLASTICS:
Molded parts for disposables, enclosures and other needs were added to the Excalibur repertoire in 1989 to meet the demand for low cost and attractive products. We have three plastic designers who each specialize in providing an attractive look, functional/structural integrity and fit for the design. Close care when designing for stress, strain and impact have resulted in near zero failure of our plastic products in the field. Each design is carefully reviewed and supported all the way through mold making and approval. We can help our customers assess their needs and budget when considering: tooling materials, number of cavities, cycle times and plastic materials.

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OPTICS:
Our founder brought optics into Excalibur and it has been with us ever since. We can do classic optics, spectrometers, endoscopes, light sources, interferometers, pyroelectrics and low bandwidth fiber optics. Our optics associate Rich Rallison is world known in holographics and gratings. While we will never be all things in optics, where optics and products combine, there are few techniques that we would be hard pressed to incorporate.

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PROTOTYPING:
Excalibur supports a wide range of prototyping abilities including software, electronics, mechanics, plastics and enclosures. These abilities make the process of creating a new product relatively effortless for our customers and produce a key focal point in defining and refining the conceived product. As a logical adjunct to Industrial Design and Model making, the prototype really gets at the product operation and utility in a "rubber meets the road" fashion. Excalibur excels at prototyping and functionality by bringing clarity and definition to your new product.

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VALIDATION:
Validation is best understood in Medical product design, but is essential for all new products. How the product is verified and validated for operation and application to the market is key to having the product work without recall and be successful in the market place. Validation begins with the product idea and carries on throughout the design and life of the product. Excalibur has utilized validation protocols since the late 70's. We write the specific design documents needed for Good Manufacturing Practices GMP. And expect to create the Device Master Records needed for proper transfer of designs to manufacturing.

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DOCUMENTATION:
Excalibur is fastidious about documentation. Each product we design will have Drawings, Processes, Schematics, Bills of Materials, Software source code and any specific instructions or process that need to be documented. This process of documentation allows the product to move directly into manufacturing with little or no hassle. We support both electronic and paper files and maintain the files in both our location and our customers hands throughout the development process, to insure that the information is current, valid and protected.

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