The SuperIRIS prototype required a highly complex PCBA with a dense layout and a large number of miniature components placed in extremely close proximity. This presented a significant challenge for the SMT (Surface Mount Technology) process, demanding exceptional precision and control to ensure accurate placement and avoid assembly defects. Adding to the complexity, the project was under intense time pressure—with only 10 days available to complete the build in time for a critical demo at the CES show in Las Vegas.

To meet both the technical and time challenges, PICCA implemented a fast-track production strategy. The engineering team conducted an immediate DFM (Design for Manufacturing) review to identify potential risks in the densely packed PCBA layout. Adjustments were made collaboratively with the client to optimize for manufacturability without compromising design intent.

PICCA then mobilized its high-precision SMT line, capable of handling ultra-small components with very small spacing. Production was scheduled with priority, and experienced operators were assigned to oversee critical stages of the process. Through meticulous planning and close monitoring, PICCA successfully completed the assembly within the tight 10-day window, ready for CES demo deployment.