Jig Upgrade, Device Progress and More...

We’ve got some important updates on BLEShark Nano production. Let’s jump in:

1. 🧊 Injection Mold Samples Are Here!

We’ve received photos of the T0 enclosure samples from our injection molding manufacturer, and they’re looking solid: fewer molding cracks and the improved 3D model! Take a look:

During their internal quality check, the manufacturer noticed a small missing structural detail in one section of the mold (see image below). However, it looks minor and seems unlikely to impact the enclosure’s fit or functionality. Once we’ve reviewed the samples in person and confirmed it’s non-critical, we’ll move forward with full molding production.

2. 🇺🇸 U.S. Assembled PCBs Have Arrived

All of our U.S.-assembled boards are in-house!

We've made final tweaks to the hardware testing jig before kicking off full production. Once we begin, each unit goes through:

• Battery soldering
• Antenna connection
• Full functional testing
• Final boxing (waiting on manuals & enclosures)

3. 🧪 Testing Jig Upgrades

We’ve upgraded the testing jig with a new 3D-printed enclosure and significantly improved its validation features. 

It now performs a lot of automated checks in seconds - deauth attacks, AP spam, button functionality, battery voltage, partition sizing, SPIFFS, BLE, IR, ESP-NOW, JSON transmission over AP, serial numbers, and even a complete OTA update check with checksum verification. Check it out in action below:

 

4. 🖥️ PCB Sneak Peek

We are actively making and testing each device. Here are some BLEShark Nano boards that have just finished battery assembly and are now waiting for final testing and enclosure fitting:

5. 🔐 OTA Update Improvements

We’ve migrated away from GitHub to our own custom CDN for OTA updates. Why?

• Encrypted OTA downloads (HMAC-authenticated per device)
• Faster boot and update times
• Version checking now uses our custom API endpoint instead of fetching the entire GitHub repo.

This makes the entire firmware process faster, safer, and more scalable.

We can’t thank you enough for your patience and continued support. We’re doing everything we can to ship as soon as possible, without compromising quality.

If you want to follow along more closely or just hang out, join our Discord community.