Challenge
Allthenticate is a forward-thinking startup dedicated to bringing innovative solutions to the cybersecurity landscape. Allthenticate worked closely with Sparx to develop an access control proximity-based authentication device capable of locking and unlocking doors based on wireless connectivity.
At a high level, the device needed to:
- Accept 12-24V DC
- Determine cell phone proximity via Bluetooth
- Connect to facility Wi-Fi
- Integrate with Allthenticate user software
- Fit within a light fixture switch housing
- Provide visual indication of lock status
- Drive a 12V or 24V DC power lock
Solution
Sparx Engineering prepared, designed, and delivered a custom embedded solution that met all requirements. This solution included three PCBs (printed circuit boards) and a soft-tooled injection-molded enclosure for full production.
Sparx maintained engineering support after the project was completed by facilitating mold vendor and PCB fabrication support. We also worked with Allthenticate to ensure seamless integration with their proprietary software.
Sparx Capabilities Demonstrated
- Embedded hardware development
- Power optimization
- Bluetooth, Wi-Fi, ethernet functionality
- Software integration advising
- Injection molded enclosure
- Functional safety design (FCC certified)
- Production management
Architecting Success with Nordic Semiconductor
When Allthenticate engaged Sparx to improve their door access control product, they already had a first-generation Raspberry Pi-based system that worked well. However, Sparx improved the following:
- BOM cost optimization
- Supply chain security with more available parts and fewer sole-sourced components
- Improved thermal performance with higher-rated components in a lower-power package
- Smaller physical package that was easier to install
- Modern industrial design
- Interchangeable power supply modules to allow AC mains input or PoE deployment
Prioritizing Quality Where It Counts
While many things can be optimized for cost, no one wanted to cut corners on reliability, so the device needed a quality wireless radio.
The heart of Allthenticate’s access control platform is a simple and convenient user experience that “just works.” Their product uses a Bluetooth Low Energy (BLE) radio to identify the phones of authorized users as they approach, unlocking the door without any required user interaction. The BLE radios on the first-generation Raspberry Pi and the selected system-on-module (SOM) could only manage 2–3 simultaneous links with incoming phones. This led to poor responsiveness as the software struggled to juggle this limited resource.
To explore other options, Sparx and Allthenticate collaborated on a prototype using an NRF52-DK with open-source Nordic firmware as a BLE adapter and immediately achieved 10 simultaneous connections. The final design included a low-cost, FCC pre-certified NRF52 module, and the system performance has been excellent.
Bluetooth radios have become commonplace in everything from toothbrushes to water bottles, with some estimates suggesting more than twice as many radios are produced as there are humans on the planet. Sparx’s experience with Nordic’s products shows that not all radios are created equal. At Sparx, we have used Nordic chipsets in several designs and have never regretted the decision from a cost, performance, or ease-of-integration perspective.
Electronics
Sparx designed a compact carrier board for an off-the-shelf system-on-module (SOM), Bluetooth Low Energy (BLE) module, and radar module. This carrier board was responsible for communicating with users’ phones and access readers to unlock/lock electronic door locks and providing power to external access readers.
Daughterboards
Sparx also designed two daughterboards enabling AC and PoE power conversion for the carrier board. The daughterboard architecture allowed for integrating the Allthenticate product into an existing network and providing compact power solutions by delivering power over Ethernet (PoE) or tapping into AC lines nearby.
Additional Electronic Elements
Connectors, LEDs, cabling, and other electronics were also selected to ensure all requirements were met. Notably, Sparx reduced the power consumption of the existing prototype by 50% by implementing efficient on-board power solutions and power staging.
The two daughterboards enabled a compact and modular power solution, eliminating the need for additional external power supplies.
Mechanics
Sparx developed an injection-molded enclosure design for Allthenticate. This allowed Allthenticate to achieve high consistency, aesthetics, and cost-effectiveness for their large volumes. The enclosure consists of two separate elements. The first is the PCB housing, which uses mounting holes to align the PCBs.
The second is the front enclosure half, that is seen by the user when in use. This half needed to clearly indicate the lock/unlock status as well as prevent light leak from the LEDs.
Project Outcome
The Allthenticate product is modular, sleek, and optimized for mass manufacturing. Allthenticate has continued to be a close partner for Sparx as the device will be iterated and improved over many generations.
Allthenticate Feedback
“Having an engineering partner like Sparx on our project made all the difference. Their experienced team was able to overcome every challenge efficiently in order to produce an exceptional product. I highly recommend Sparx.” – Chad Spensky Allthenticate CEO