Erae2 is a very complex electronic product with complicated metal casing that requires high precision and flawless finishing and also with complex PCBA mounting. Also, the product assembly is rather complicated as it involves many parts and components provided by not just PICCA but also from other partners. Improving the manufacturability of the design was a big challenge as we need to coordinate all the parts together since one small change on one metal piece would have impacts on all the other parts when it comes to fitment. Also, due to the extra time spent on product development since it’s such a complicated product, the time left for production was very limited, and also within this very limited timeframe, Picca had to constantly adapt to the delivery schedules from other component providers, making it even more difficult for a on-time delivery. We had to cope with the defects on components from other factories.

PICCA engaged early in the development process, supporting Embodme from the R&D stage with a detailed Design for Manufacturing (DFM) review focused on the mechanical structure. This early involvement enabled us to proactively identify potential manufacturing challenges and propose optimizations before moving into production. We also provided an initial cost analysis to help Embodme evaluate project profitability and make informed decisions on component sourcing and design adjustments. Throughout the project, PICCA played a key coordinating role—aligning with multiple external suppliers, resolving fitment issues caused by design dependencies, and rapidly adapting the assembly plan in response to shifting delivery timelines. Our team also stepped in to manage and rework defective components from other partners to ensure overall product integrity.