Driving Forward FOX's Suspension Control System with the Touchpoint
The Challenge
FOX approached Hatch for assistance with a critical project involving the development of the FOX Touchpoint, an advanced suspension and ride control system. FOX required the product to meet strict standards for off-road performance and attention to detail in a thin, compact device. Additionally, the spring-loaded toggle paddles required a design and manufacturing partner capable of ensuring exceptional precision and quality. Ingress protection (IP) standards added another layer of complexity, necessitating Hatch’s specialized expertise to commercialize and refine the product effectively.
Development of FOX's Touchpoint
FOX came to Hatch with an early prototype and appearance model that helped Hatch identify opportunities for improvement both mechanically and electrically and establish a concrete set of product requirements. This exercise enabled Hatch to assemble and accelerate their team in providing a comprehensive mechanical and electrical design while ensuring design for quality and manufacturability. In addition, Hatch supported low-level firmware development for the hardware and manufacturing end of line test. FOX provided the application-level firmware and worked closely with Hatch’s team, ensuring seamless integration for the final product.
Sourcing Unique Parts and Premium Materials for the Suspension Control System
To meet the high standards for this automotive-grade product, Hatch meticulously sourced each component, selecting materials that ensure both durability and a refined user experience. The product incorporates stainless steel, chosen for its exceptional strength and corrosion resistance, ensuring longevity in demanding automotive environments. Aluminum was utilized for its lightweight properties, allowing for precision machining while maintaining structural integrity. For the paddle mechanisms, the team leveraged cold-forged tooling, followed by an anodization process, enhancing both durability and aesthetics with a sleek, high-end finish. Panda Double Tempered glass was integrated for its scratch resistance and clarity, reinforcing the premium nature of the device. Each material was carefully selected not only to meet stringent performance requirements but to provide a premium, tactile experience, elevating the interaction between the user and the suspension control system.
Testing and Building Custom Jigs, Fixtures and Test Equipment
Hatch conducted extensive testing during Engineering Verification Testing (EVT) and Design Verification Testing (DVT) which included FCC, IC, and Bluetooth certifications. The environmental testing adhered to IEC standards, and particular attention was given to components like hinges and LED systems to ensure durability and compliance. Setting up the production line was a pivotal phase. Hatch designed and implemented custom jigs and fixtures to optimize manufacturing efficiency and quality. Hatch also has a fully custom bed of nails fixture to test and program each PCBA to ensure all electrical connections are sound and functioning correctly. Ingress protection checks were conducted on the production line to guarantee the reliability of each unit. This stage also included the execution of Production Verification Testing (PVT) builds, maintaining rigorous standards for automotive-grade quality.
Companion Cradle Integration
A standout feature of this project was the companion cradle that Hatch developed to enable seamless dashboard integration for the FOX Touchpoint. This cradle required careful consideration, including injection molding techniques and the use of carbon parts to achieve the required strength and aesthetics.
The Result
The Touchpoint allows for easy adjustments to the semi-active FOX dampers, adapting to various terrains. Using the Live Valve suspension management system, it processes real-time data from sensors and adjusts shock settings in milliseconds for optimal performance.