CONSUMER ELECTRONICS
Smart Lights Ecosystem
HARDWARE | FIRMWARE | MOBILE/WEB APPS | EMS MANUFACTURING
Project Overview
We developed a complete smart lighting product line including RGB bulbs, DC/AC smart light controllers, and a portable smart lamp. These lights support BLE/Wi-Fi connectivity and are controlled through feature-rich Android/iOS apps with over 50,000 units successfully produced and deployed globally.
Client Requirement & Objectives
Multi-Connectivity Support: The lights must be controllable over BLE or Wi-Fi, with seamless mobile app pairing and operation.
Feature-Rich Application: Required a mobile app supporting RGB color selection, brightness control, ambient modes, voice commands, music-sync, and schedule routines.
Mesh Capability: The system must support Bluetooth Mesh for simultaneous control of 1000+ lights and allow multi-app access to a single device.
End-to-End Delivery: Biggworks was responsible for hardware, embedded firmware, mobile applications, and high-volume production for retail deployment.
System Design & Build
BLE Mesh + Wi-Fi Architecture: BLE Mesh + Wi-Fi Architecture: Engineered a robust wireless system supporting both standalone Wi-Fi and scalable BLE Mesh topologies for different use-cases.
Modular Product Family: Designed and produced multiple smart lighting SKUs including RGB bulbs, AC/DC controllers, and a portable lamp with shared core electronics.
Mobile App Ecosystem: Developed native Android/iOS apps with advanced controls, device grouping, voice integration, and real-time synchronization.
Mass Production Optimization: Achieved 50k+ PCB production runs with tested DFM/DFT processes, ensuring consistent quality across multiple geographies.
Project Tech Stack
Key Challenges & Solutions
Heat Dissipation: High ambient temperatures impacted RF stability in compact enclosures. We resolved this with thermal-optimized PCB layouts and component placement for better heat dispersion.
Cost vs. Quality Balance: Manufacturing for cost-sensitive markets like India required aggressive BOM optimization. We sourced components strategically and re-engineered circuit paths without compromising performance
Mesh Scalability: Ensuring performance across 1000+ node BLE mesh networks was complex. We implemented intelligent node caching, low-latency response logic, and efficient rebroadcast protocols.
Secure Communication: Implemented AES-based encryption with device-level authentication to safeguard control messages and user data over BLE Mesh and Wi-Fi. .
Client
Banix is one of the biggest smart lighting solution providers in india. Their smart lighting products are available on sale at flipkart, amazon and other ecommerce companies in india.
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